Covering Panel With Varying Edge Cross-Section for Natural Appearance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing laminate floor panels fail to convincingly imitate natural panels, particularly in edge design, leading to suboptimal appearance and potential water leakage between panels.
Innovation Solution
The panel features a non-planar, irregularly varying lowered edge structure along its length, with a constant extreme edge for sealing, and a surface decoration that includes a separate finishing process for the lowered part, utilizing anti-adhesive application and milling techniques to achieve a natural appearance and efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flat lowered part is used at the edge of the panel, then the manufacturing process is simple, but the natural appearance of the panel is compromised
Solution Approach 1:
The patent applies local quality by creating a lowered part with varying cross-section along the edge of the panel. The cross-section changes from a first value at one location to a second value at another location, giving different regions of the edge different geometric properties. This local variation in geometry mimics natural wood edges while still being manufacturable through standard milling processes.
2Shape
If the extreme edge of panels has varying positions along the edge, then the natural appearance is improved, but water leakage between panels occurs
Solution Approach 1:
The patent distinguishes between two types of edges: the extreme edge that maintains a constant position for sealing, and other portions of the edge that have varying cross-sections for aesthetic purposes. This local differentiation ensures that the sealing function is maintained at the extreme edge while the natural appearance is achieved through variation in other regions.
3Ease of manufacture
If the lowered part has a constant cross-section along the edge, then the manufacturing process is simple, but the natural appearance is compromised
Solution Approach 1:
The patent applies parameter changes by varying the cross-sectional dimensions of the lowered part along the edge. Specifically, the cross-section changes from a first value at one location to a second value at another location. This parameter variation creates the natural appearance while remaining compatible with standard manufacturing processes.
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The invention provides a panel (1) for use in an assembly of panels (1) attached to each other to form a covering. The panel (1) comprises an upper surface (2) and a lower surface (3) each extending within a different main plain, and at least an edge (4) between these surfaces comprising coupling means (5, 6) to couple the panel (1) to coupling means (5, 6) of another panel (1). The upper surface (2) includes a lowered part (7) at said edge (4) and the cross-section of the lowered part (7), perpendicular to the edge (4) of the panel (1), varies along the edge (4). Such a panel (1) provides a good imitation of a panel made of natural materials. The invention also provides an appropriate method to make such a panel (1). The invention provides a panel which presents a very good imitation of a panel made of natural materials.