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Solution Overview
Problem
Existing floor panels made of thermoplastic materials, particularly vinyl-based panels, experience significant shrinkage and expansion issues due to temperature changes, leading to gaps and instability, especially when exposed to sunlight, and lack effective vertical locking mechanisms, resulting in poor impact sound absorption and adaptability to uneven surfaces.
Innovation Solution
The use of a panel structure comprising two layers of strewn and pressed thermoplastic granulate enclosing a glass fiber layer, preferably a glass fiber fleece, with individual fibers of specific lengths and concentrations, and a transparent wear layer, which enhances dimensional stability and wear resistance, and incorporates mechanical coupling means for secure locking in both horizontal and vertical directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastic panels are made with standard density and composition, then they are easy to manufacture and install, but they exhibit strong shrinkage and expansion under temperature changes
Solution Approach 1:
The patent applies composite materials by combining thermoplastic material with glass fiber reinforcement. The glass fiber layer is integrated into the thermoplastic matrix to create a composite structure that maintains the ease of manufacturing thermoplastic panels while significantly reducing thermal expansion and shrinkage. The glass fiber provides dimensional stability by restraining the thermoplastic material's tendency to expand and contract with temperature changes.
Solution Approach 2:
The patent changes the physical and chemical parameters of the panel by incorporating glass fiber reinforcement and adjusting the density distribution. The glass fiber content and its orientation are controlled to optimize dimensional stability. Additionally, the patent creates density variations within the panel structure, with higher density at the surfaces and lower density in the core, which helps reduce thermal expansion while maintaining manufacturability.
2Ease of operation
If panels use simple coupling means, then they are easy to assemble, but they lack vertical locking mechanism and allow panels to drift apart
Solution Approach 1:
The coupling means is segmented into multiple functional elements: horizontal locking components and vertical locking components. The horizontal coupling elements allow for easy assembly by connecting adjacent panels laterally, while separate vertical locking elements provide reliable vertical restraint. This segmentation enables each component to perform its specific function effectively while maintaining overall ease of assembly.
Solution Approach 2:
The coupling means is designed with multi-functionality to simultaneously provide horizontal locking, vertical locking, and adjustment capabilities. The same coupling mechanism handles both lateral connection and vertical stabilization, reducing the number of separate components needed while ensuring reliable panel retention in all directions.
3Quantity of substance
If panels are made thinner to reduce material usage, then they are more cost-effective, but they lack adaptability to uneven surfaces and impact sound absorption
Solution Approach 1:
The patent applies local quality by creating non-uniform density distribution within the panel thickness. The surface layers have higher density to provide wear resistance and dimensional stability, while the core layer has lower density to provide flexibility and adaptability to uneven surfaces. This localized variation in material properties allows thin panels to maintain both cost-effectiveness and functional performance.
Solution Approach 2:
The composite structure combines thermoplastic material with glass fiber reinforcement in a layered configuration. This composite approach allows thin panels to achieve adequate stiffness and surface adaptability through the synergistic combination of materials, rather than requiring increased thickness of a single material.
4Stability of the object's composition
If glass fiber reinforcement is added to increase dimensional stability, then shrinkage and expansion are reduced, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes the porous or fibrous structure of glass fiber materials that can be easily integrated into thermoplastic matrices. The glass fiber layer is designed with a structure that allows straightforward incorporation during the thermoplastic processing stages, minimizing additional manufacturing steps while achieving the desired dimensional stability.
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
This solution significantly reduces the extent of expansion and shrinkage, provides improved stability and wear resistance, and ensures a secure locking mechanism, maintaining panel quality and stability over time, while allowing for adaptability to uneven surfaces and maintaining transparency.
Implementation Method 1
The panels of the state of the art show the disadvantage that they are strongly subjected to shrinkage and expansion, or even bending, under the influence of temperature
Implementation Method 2
the aforementioned two layers substantially consist of a strewn and pressed granulate, wherein the respective layers enclose a glass fiber layer
Implementation Method 3
comprises coupling means or coupling parts with which two of such floor panels can be coupled at said edges in such a manner that they are mutually locked in a horizontal direction perpendicular to the respective edge and in the plane of the floor panels, as well as in a vertical direction perpendicular to the plane of the floor panels
Data Source
Figure 1~4
AI summary
Panel comprising at least a substrate (11) of thermoplastic material and a top layer (13) with a printed decor and a translucent or transparent wear layer (6), characterized in that said substrate substantially consists of three layers, including a lowermost layer, a central layer and an uppermost layer, all made from thermoplastic material, wherein the thermoplastic material of the lower most layer and the uppermost layer is more rigid than the thermoplastic material of the central layer.