Polymer Core Panel With Integrated Decorative Wear Layer
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Solution Overview
Problem
Existing floor coverings with polymer cores, such as PVC, require complex production processes due to separate decorative and wear-resistant layers, limiting decorative possibilities and increasing thickness, which can detract from the quality of the decor.
Innovation Solution
A panel with a polymer core that integrates a granular and/or fibrous material as a single decorative and wear-resistant layer, eliminating the need for separate layers, allowing varied decoration and enhanced wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate decorative layer and wear-resistant layer are applied on the polymer core, then wear resistance is improved, but the production process becomes complex and decorative possibilities are limited
Solution Approach 1:
The patent combines the decorative layer and wear-resistant layer into a single integrated top layer. This top layer contains colorants for decoration and abrasion-resistant particles for wear protection, eliminating the need for separate layers and simplifying the production process while maintaining both aesthetic and functional properties
Solution Approach 2:
The top layer is formulated as a composite material containing a polymer matrix, colorants for decorative purposes, and abrasion-resistant particles. This composite structure provides both aesthetic appearance and wear resistance within a single layer, resolving the contradiction between functional requirements and process simplicity
2Reliability
If separate decorative layer and wear-resistant layer are applied, then wear resistance is improved, but the number of layers increases which may affect decor quality
Solution Approach 1:
The patent merges multiple functional layers into a single top layer that simultaneously provides decoration and wear resistance. This reduces the total number of layers in the panel structure, preventing the decor quality from being compromised by excessive layering while still achieving the desired wear resistance
3Reliability
If traditional separate layers are used, then wear resistance can be achieved, but decorative possibilities are limited
Solution Approach 1:
The top layer is designed as a versatile composite material system where the polymer matrix can be formulated with different colorants, pigments, and abrasion-resistant particles. This composite approach enables a wide range of decorative options while maintaining wear resistance, as the various components can be adjusted and combined in different proportions and configurations
Solution Approach 2:
The top layer allows for local variation in composition and properties, enabling different decorative patterns, colors, and textures to be achieved in different regions of the panel. The abrasion-resistant particles can be distributed uniformly or selectively to provide both aesthetic variety and functional protection
Data Source
AI summary
A panel includes a substantially plate-shaped polymer core and a decorative and/or wear-resistant layer. The decorative and/or wear-resistant layer is bonded at least partially to and/or in a surface of said polymer core, and the decorative and/or wear-resistant layer comprises a granular and/or fibrous material.