Multilayer Wood Flooring Panel With Oak Veneer and Stabilizing Layer
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Solution Overview
Problem
Existing wood flooring panels inefficiently utilize high-value materials like oak, leading to excessive resource consumption and high production costs, while lacking in eco-sustainability and durability.
Innovation Solution
A four-layer wood panel structure comprising birch plywood, solid hardwood, non-woven fabric, and oak veneer, bonded with vinyl or polyurethane glue, optimizing the use of less valuable materials to achieve the same aesthetic and mechanical properties as traditional oak panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If traditional two-layer wood flooring panels are used with high-quality oak for the surface layer, then aesthetic quality is improved, but resource consumption increases and production costs rise
Solution Approach 1:
The patent applies composite materials by creating a four-layer structure combining birch plywood base, hardwood core, oak veneer surface layer, and non-woven fabric intermediate layer. This composite construction allows the use of thin oak veneer (0.6-1mm) instead of thick solid oak, maintaining aesthetic quality while significantly reducing oak consumption and production costs.
Solution Approach 2:
The patent applies local quality by assigning different material properties to different layers: the surface layer uses high-quality oak veneer for aesthetics, the core uses hardwood for mechanical strength, the base uses birch plywood for stability, and the intermediate layer uses non-woven fabric for adhesion. Each layer is optimized for its specific function, reducing overall material consumption while maintaining performance.
2Ease of manufacture
If traditional wood flooring panels are used without intermediate stabilizing layers, then manufacturing simplicity is maintained, but durability and adhesion between layers deteriorate
Solution Approach 1:
The patent applies the intermediary principle by introducing a non-woven fabric layer between the hardwood core and oak veneer surface layer. This intermediate layer acts as a mediator that enhances adhesion between layers, improves durability, and provides stabilization, while still being compatible with standard manufacturing processes using vinyl or polyurethane glue.
3Illumination intensity
If thick surface layers of oak are used, then aesthetic quality is improved, but wear resistance and longevity are reduced
Solution Approach 1:
The patent applies parameter changes by optimizing the thickness of the oak surface layer to 0.6-1mm, which is thinner than traditional solid oak flooring but sufficient when combined with a dense hardwood core and stabilizing intermediate layer. This parameter optimization maintains aesthetic quality through the visible oak veneer while improving wear resistance and longevity through the composite structure's overall stability and resistance to deformation.
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
Reduces oak usage, enhances durability and eco-friendliness, while maintaining quality and reducing production costs, with improved wear resistance and sustainability.
Implementation Method 1
an intermediate layer made of non-woven fabric, preferably 0.2 mm ± 0.05 mm thick, used to improve the adhesion between the central layer and a surface layer, and ensure that the surface layer made of oak veneer is more resistant and stable
Implementation Method 2
The composition of the new panel is carried out by gluing said layers with vinyl glue, applied hot and cold, or polyurethane glue
Implementation Method 3
The new panel is then coated with a combination of compounds suited to make the surface layer highly resistant and therefore suitable for intense foot traffic
Data Source
Figure 1~2
AI summary
The invention is a multilayer wood panel (P) for flooring, comprising a bottom layer or base (1) made of birch plywood, a central layer (2) made of hardwood and a surface layer (3) made of oak veneer, and wherein a stabilizing layer made of non-woven fabric (4) is preferably interposed between said central layer (2) and said surface layer (3).