Mineral Wool Carrier Floor Panel Dimensional Stability
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Solution Overview
Problem
Floor covering panels made from materials like gypsum fiber boards and fiber cement panels face issues with dimensional changes due to humidity and temperature fluctuations, leading to aesthetic and functional problems, and are difficult to process and connect without adhesives.
Innovation Solution
A floor covering panel with a carrier layer made of compacted mineral wool, rock wool, or glass wool fibers, combined with a binder, featuring profiled edges for interlocking and a decorative coating, which is dimensionally stable and resistant to moisture and temperature changes, allowing for easy assembly without adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If gypsum fiber boards or fiber cement panels are used as carrier layers, then the floor covering panels can be produced with simple materials, but they undergo dimensional changes due to humidity and temperature fluctuations, leading to profile opening and loss of function
Solution Approach 1:
The patent uses a composite material consisting of mineral wool fibers (rock wool and/or glass wool) combined with a binder to create a carrier layer that is dimensionally stable. This composite structure prevents the profile opening and bulging issues experienced with gypsum fiber boards and fiber cement panels, while maintaining ease of manufacture through standardized production processes.
2Stability of the object's composition
If fiber cement panels are used as carrier layers, then the floor covering panels gain dimensional stability, but they become difficult to process and connect without adhesives
Solution Approach 1:
The patent employs a composite material of mineral wool fibers with binder that provides both dimensional stability and improved processability. Unlike fiber cement panels, this composite can be easily profiled and connected using locking profiles without adhesives, while maintaining the dimensional stability needed to prevent profile opening and bulging.
3Ease of manufacture
If conventional carrier layers are used, then the floor covering panels can be produced simply, but they lose strength under permanent humidity and suffer total loss of function
Solution Approach 1:
The patent uses a composite material consisting of mineral wool fibers (rock wool and/or glass wool) combined with a binder to create a carrier layer that maintains its strength under permanent humidity. This composite structure prevents the total loss of function experienced with conventional carrier layers, while maintaining production simplicity through standardized manufacturing processes.
4Ease of operation
If locking profiles are used to connect components without adhesive, then the floor covering panels can be assembled simply, but exact profiling and assembly become much more difficult with hard materials like fiber cement
Solution Approach 1:
The patent employs a composite material of mineral wool fibers with binder that can be easily profiled to achieve exact dimensions for locking profile connections. Unlike hard materials like fiber cement, this composite allows for precise profiling and straightforward assembly without adhesives, while maintaining dimensional stability to prevent profile opening.
Data Source
Figure 1
AI summary
The invention relates to a floor covering panel with a carrier layer. In order to provide floor covering panels for a floor covering that do not react to temperature fluctuations or humidity fluctuations with dimensional changes, it is provided that the carrier layer comprises compressed mineral wool and a binder.