Magnesium Oxide Floor Panel with Reinforcing Layer
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Solution Overview
Problem
Conventional wood-based and PVC-based floor panels face issues with hygroscopicity, aesthetic unevenness, susceptibility to temperature changes, and lack of fireproof properties, necessitating a material that is waterproof, dimensionally stable, and adjustable in thickness while maintaining strength.
Innovation Solution
A magnesium oxide-based floor panel with a high-density upper crust layer and a reinforcing layer, where the magnesium oxide core and crust layers provide fire resistance, water resistance, and dimensional stability, and the reinforcing layer enhances strength and allows for adjustable thickness through sanding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If wood-based materials are used for floor panels, then aesthetic appearance is improved, but hygroscopicity increases leading to reduced lifetime and durability
Solution Approach 1:
The patent employs a composite structure with a wood-based decorative layer providing aesthetic appearance and a magnesium oxide-based core layer providing dimensional stability and fire resistance. This composite approach allows the panel to simultaneously achieve visual appeal and long-term durability without the hygroscopic problems of pure wood materials.
2Reliability
If PVC is used as core material, then water resistance is improved, but susceptibility to temperature changes increases causing expansion and contraction
Solution Approach 1:
The patent changes the material parameter from PVC to magnesium oxide in the core layer. Magnesium oxide provides both water resistance and exceptional dimensional stability with minimal thermal expansion, eliminating the expansion-contraction problems associated with PVC while maintaining waterproof properties.
3Manufacturing precision
If thickness is reduced for uniformity, then aesthetic flatness is improved, but panel strength decreases
Solution Approach 1:
The patent uses a composite structure with a dense magnesium oxide core layer that provides high strength-to-weight ratio. This allows the panel to maintain uniform thin dimensions for aesthetic flatness while the inherently strong magnesium oxide material ensures sufficient structural strength is retained.
4Object-affected harmful factors
If magnesium oxide based materials are used, then fire resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the floor panel into distinct functional layers: a magnesium oxide-based core layer for fire resistance and structural integrity, and a separate wood-based decorative layer for aesthetics. This segmentation allows each layer to be optimized independently and simplifies manufacturing by using standardized layering processes.
Data Source
AI summary
The invention relates to a floor panel, in particular a magnesium oxide based floor panel, which is preferably provided with interconnecting coupling parts for mutually connecting adjacent floor panels to each other. The invention also relates to a method of producing a floor panel, in particular a magnesium oxide based floor panel.