Building panel and method to produce such panel
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Solution Overview
Problem
Conventional carpet flooring is difficult to install, remove, and recycle due to its large and heavy size, leading to material waste and inefficiencies in material use and recycling.
Innovation Solution
A building panel system featuring a substrate with a surface layer of decorative carpet fibers, where both the substrate and surface layer binder are made from the same type of polymer, allowing for easy assembly, disassembly, and recycling without material separation, using a mechanical locking device for connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional carpet flooring is used, then a soft and warm feeling is provided, but the flooring becomes difficult to install, remove, and recycle due to large and heavy size
Solution Approach 1:
The invention divides the conventional large and heavy carpet flooring into smaller, manageable building panels that can be easily handled, installed, and removed. Each panel maintains the desired carpet-like surface properties while reducing the weight and size for easier operation.
Solution Approach 2:
The invention changes the physical parameters of the flooring by transitioning from large rolls to smaller panels with optimized dimensions and weight, while maintaining the essential functional properties of softness and warmth through the carpet fibers.
2Adaptability or versatility
If conventional carpet flooring is used, then design flexibility is provided, but material recycling becomes difficult leading to waste
Solution Approach 1:
By segmenting the flooring into standardized panels, the invention enables selective replacement of only damaged or worn panels rather than the entire flooring system, significantly reducing material waste while maintaining design flexibility through panel selection and arrangement.
Solution Approach 2:
The invention facilitates the recovery and recycling of flooring materials by enabling easy removal and separation of panels, allowing usable materials to be recovered and reused rather than discarded with the entire flooring system.
3Area of stationary object
If conventional carpet flooring is used, then coverage area is achieved, but installation and replacement of smaller areas becomes nearly impossible
Solution Approach 1:
The invention segments the flooring into individual replaceable panels, making it possible to remove and replace only the specific panels that are worn or damaged, thereby enabling easy repair of smaller areas while maintaining overall coverage.
Solution Approach 2:
The flooring system is pre-configured as modular panels that can be independently handled and replaced, allowing preliminary preparation of replacement panels without affecting the rest of the installed flooring system.
Data Source
AI summary
A building panel having a substrate and a layer arrangement, arranged on one side of the substrate. The layer arrangement having a surface layer and where the surface layer includes carpet fibres. At least the substrate at least partly includes a mechanical locking device for connecting at least two building panels. Where the substrate and the layer arrangement each includes a polymer of the same type of polymer.