Decorative Panel Grout Imitation via Bevels and Recesses
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Solution Overview
Problem
Existing decorative panels that simulate ceramic or natural stone tiles lack a realistic grout imitation, requiring a separate grouting operation after installation.
Innovation Solution
The panels feature a substrate with a top layer comprising a decor layer and a wear layer, including printed films, and are equipped with coupling parts and mechanical locking elements that create a realistic grout imitation through recesses and bevels, eliminating the need for post-installation grouting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If decorative panels simulate ceramic or natural stone tiles, then the aesthetic appearance is improved, but the grout realism is insufficient requiring separate grouting operations
Solution Approach 1:
The grout imitation is created during the panel manufacturing process by forming recesses and applying bevels to the top layer, rather than requiring grouting after installation. This preliminary action integrates the grout effect into the panel itself, eliminating the need for separate post-installation grouting operations while maintaining realistic appearance.
Solution Approach 2:
The invention merges the tile surface and grout joint features into a single integrated panel structure. The recesses and bevels on the top layer combine to create both the tile appearance and the grout imitation simultaneously, eliminating the need for separate grouting operations and simplifying installation.
2Shape
If recesses and bevels are added to create grout imitation, then the aesthetic appearance is improved, but the manufacturing complexity increases
Solution Approach 1:
The top layer is segmented into distinct functional zones: the decorative surface area and the recessed grout imitation areas. This segmentation allows the panel to represent multiple elements (tile and grout) within a single component, creating realistic appearance while managing structural complexity through functional division.
Solution Approach 2:
Different regions of the panel top layer are given different geometric properties: the tile surface area maintains a flat, smooth finish for realistic tile appearance, while the grout areas feature recesses with bevels for realistic grout appearance. This local differentiation of quality creates the grout imitation effect without requiring the entire panel to be complex.
3Stability of the object's composition
If coupling parts with mechanical locking elements are provided, then the connection stability is improved, but the installation time increases
Solution Approach 1:
The coupling parts are designed with mechanical locking elements that automatically engage and secure panels to each other during installation. The locking mechanism self-activates as panels are joined, providing stable connections without requiring additional fastening operations or complex installation procedures, thus maintaining installation efficiency.
Data Source
AI summary
A panel includes a substrate and a top layer. The top layer has a decor layer and a wear layer. The decor layer includes a printed film. The panel is provided with a first pair of opposite edges, having coupling parts in the form of a tongue and a groove with locking parts. The male edge defines a recess for providing a simulation of grout in coupled condition of the panels. The female edge defines a distal portion which overlaps in coupled condition at least partly the recess at the male edge. The male edge and the distal portion each form a bevel. These bevels extend with an angle with the surface of the panel between 15° and 45° through the printed film.