Mineral Wool Floor Panel with Decorative Layer
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Solution Overview
Problem
Existing floor panels based on cement or cement fibers lack sufficient strength and rigidity, are prone to warpage, and have limited resistance to moisture and fire, making them unsuitable for high-stability and moisture-sensitive applications.
Innovation Solution
A panel-shaped floor element with a carrier board made of compacted mineral wool, pressed with thermosetting synthetic binders, achieving a density of 800-1500 kg/m3 and transverse tensile strength of 2.5-6.0 N/mm2, combined with a decorative layer of resin-impregnated paper or fleece, and featuring a multi-layer structure with a bonded powder mixture for enhanced adhesion and abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If carrier plates are made from cement or cement fibers, then fire resistance is improved, but strength and rigidity deteriorate
Solution Approach 1:
The patent uses a composite structure combining an HDF carrier plate (providing strength and rigidity) with a decorative layer containing fire-retardant additives (providing fire resistance). This composite approach allows both requirements to be met simultaneously - the HDF core provides mechanical strength while the fire-retardant decorative layer provides fire protection without compromising the structural integrity of the floor panel.
2Object-affected harmful factors
If carrier plates are made from cement or cement fibers, then fire resistance is improved, but stability and warpage resistance deteriorate
Solution Approach 1:
The HDF carrier plate provides dimensional stability and resistance to warping due to its high-density cross-linked fiber structure, while the fire-retardant decorative layer provides fire protection. The composite structure allows the stable HDF core to maintain geometric integrity while the outer layer provides fire resistance, resolving the contradiction between fire safety and dimensional stability.
3Object-affected harmful factors
If carrier plates are made from cement or cement fibers, then fire resistance is improved, but moisture resistance deteriorates
Solution Approach 1:
The HDF carrier plate acts as an intermediary layer between the moisture environment and the decorative layer. HDF's dense fiber structure provides inherent moisture resistance, protecting the core structure from water damage while allowing the decorative layer to provide fire retardancy. This mediator approach allows both fire resistance and moisture resistance to coexist without compromising either function.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a highly stable, low-warpage, moisture-insensitive, and fire-resistant floor panel suitable for wet areas, with improved mechanical properties and no need for post-treatment, offering a ready-to-use surface with excellent durability and aesthetic finish.
Implementation Method 1
the moisture produced when the decorative layer and the carrier board are pressed together can diffuse to the required extent into the carrier board
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a panel-shaped building element, in particular a floor panel 1. The building element has a carrier panel 5 with a decorative layer 6 on its upper surface. This layer comprises a flat decorative substrate 7, in particular a decorative paper. The carrier panel 5 consists of compressed mineral wool with a high density of greater than or equal to (≥) 800 kg/m³ and a transverse tensile strength of greater than 2.5 N/mm². The side edges 11, 12 of the carrier panel 5 are profiled and provided with locking means 13, 14. The carrier panel 5 and the decorative layer 6 are pressed together.