Laminated Waterproof Panel With Rigid Support Layer
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Solution Overview
Problem
Existing waterproof floor and wall coverings face challenges in achieving adequate rigidity, resistance to indentation, and sound dampening while maintaining waterproof and acoustic properties.
Innovation Solution
A panel with a laminated structure comprising a flexible core layer with a low density and a rigid support layer with a high density, where the thickness of the core layer is smaller than the support layer in a ratio of 0.5 or less, and the support layer is directly or indirectly provided on top of the core layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick core layer is used to improve waterproof and acoustic properties, then waterproof quality and sound dampening are improved, but rigidity and resistance to indentation are compromised
Solution Approach 1:
The patent uses a composite structure combining a flexible foam core layer with a rigid support layer. The core layer provides waterproof and acoustic properties, while the support layer compensates for the lack of rigidity in the foam material, achieving both waterproof quality and structural strength simultaneously
Solution Approach 2:
The panel is divided into functionally distinct layers: a core layer dedicated to waterproofing and sound dampening, and a separate support layer dedicated to providing rigidity and indentation resistance. This segmentation allows each layer to optimize its specific function without compromising the other
2Reliability
If a thick core layer is used to improve acoustic properties, then sound dampening is improved, but the panel becomes more susceptible to deformation
Solution Approach 1:
The combination of flexible foam core with rigid support layer creates a composite structure where the rigid layer restrains the foam core from deforming under temperature and humidity cycles, maintaining dimensional stability while preserving acoustic performance
Solution Approach 2:
Different regions of the panel have different mechanical properties: the core layer is soft and flexible for acoustic absorption, while the support layer is rigid for dimensional stability. This local differentiation of material properties resolves the contradiction between acoustic performance and deformation resistance
3Reliability
If the core layer thickness is increased to improve waterproof properties, then waterproof quality is improved, but indentation performance deteriorates
Solution Approach 1:
The rigid support layer acts as a protective shell over the flexible waterproof core, providing indentation resistance while the core layer maintains its waterproof function. The composite structure achieves both waterproof quality and surface durability
Data Source
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AI summary
Panel suitable for assembling a waterproof floor or wall covering from a plurality of said panels, wherein the panel has a substantially planar top surface, and a substantially planar bottom surface, the panel having a laminated structure of layers which comprises: - a flexible core layer which basically is composed of a material which is relatively low in density and is provided with voids in the form of air pockets, and - a rigid top layer which comprises a support layer that is basically composed of a material that is relatively high in density and which is virtually devoid of air pockets, wherein the thickness of the core layer is smaller than the thickness of the support layer, preferably in a ratio of 0.5 or less, more preferably in a ratio between 0.5 and 0.10.