A mineral-based panel comprising grooves
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Solution Overview
Problem
Existing mineral-based boards, such as magnesium oxide and cement boards, are heavy and lack robust locking systems, necessitating improvements for reduced weight, material content, and cost-effective production while maintaining properties like dimensional stability and sound insulation.
Innovation Solution
A mineral-based panel with grooves and a locking system, comprising a mineral-based core and polymer-based layers, where grooves are formed to reduce weight and enhance sound properties, and a locking system is integrated for improved stability and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If grooves are added to the mineral-based panel, then weight and material content are reduced, but structural integrity may be compromised
Solution Approach 1:
The patent applies the porous materials principle by incorporating grooves into the mineral-based panel that create a controlled porous structure. These grooves reduce the overall material content and weight of the panel while maintaining structural integrity through the strategic design of the groove pattern and depth, allowing the panel to achieve weight reduction without compromising its load-bearing capacity.
Solution Approach 2:
The patent applies segmentation by dividing the panel structure into distinct regions through the grooves. This segmentation creates multiple zones within the panel that can independently contribute to structural support, allowing the grooves to remove material while the remaining segments maintain the necessary strength and stability for floor panel applications.
2Object-affected harmful factors
If grooves are added to the mineral-based panel, then sound properties are improved, but manufacturing complexity increases
Solution Approach 1:
The groove structure segments the panel into multiple zones that create sound-absorbing cavities and pathways. This segmentation approach improves sound insulation by disrupting sound wave propagation while the grooves can be integrated into existing panel manufacturing processes, minimizing the increase in manufacturing complexity.
3Reliability
If a locking system is integrated into the panel, then installation stability is improved, but device complexity increases
Solution Approach 1:
The patent merges the locking system with the panel structure itself, integrating the locking mechanism directly into the panel edges rather than using separate, standalone locking components. This merging approach provides robust installation stability while minimizing the increase in device complexity by combining multiple functions into a unified structural design.
Solution Approach 2:
The locking system is designed to perform multiple functions simultaneously - providing mechanical interlocking between panels, ensuring vertical alignment, and preventing lateral movement. This multi-functionality reduces the need for separate components, thereby improving installation stability without proportionally increasing device complexity.
Data Source
Figure 1a~1c
Figure 2a~2e
Figure 3a~3g
AI summary
There is disclosed a mineral-based floor panel (1) comprising a mineral-based core, wherein the panel comprises at least one groove (19). The at least one groove (19) may be provided in a rear side (4) of the panel. There is also disclosed other such mineral-based panels, such as a building panel, a wall panel, a ceiling panel or a furniture panel. There is also disclosed a method for forming such grooves (19) in a mineral-based panel.Furthermore, there is disclosed a mineral-based panel (1) comprising a mineral-based core and polymer-based lower layer(s)attached to the core. A locking system of the panel comprises a strip extending horizontally beyond an upper portion of the panel, wherein at least a horizontal portion of the strip is entirely formed in the polymer-based lower layer(s).