Pressed Floor Panel Chamfers With Protected 3D Joint Depth

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Solution Overview

Problem

Existing methods for manufacturing floor panels with chamfers result in shallow bevels that are not well-protected, leading to visible joints that are prone to damage and color peeling due to abrasion.

Innovation Solution

The method involves pressing a chamfer into the floor panel with a specific insertion depth and applying an overlay containing abrasion-resistant particles to enhance the optical depth of the chamfer, while also incorporating a color gradient to create a 3D effect.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If chamfers are pressed into the floor panel surface, then the visual depth effect is improved, but the surface protection and abrasion resistance deteriorate

Engineering Contradiction:

Improvechamfer depthVSAvoidsurface protection

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The overlay with abrasion-resistant particles is applied before pressing the chamfer. This preliminary action ensures that the protective layer is already in place before the pressing process, preventing damage to the underlying surface and maintaining abrasion resistance in the chamfer area.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The floor panel uses a composite structure with an overlay containing abrasion-resistant particles (such as aluminum oxide or silicon carbide) bonded to the panel surface. This composite material provides both the visual depth effect of the chamfer and the necessary surface protection and wear resistance.

Inventive Principle:

Principle #40Composite materials

2Shape

If chamfers are milled to create deeper joints, then the visual depth effect is improved, but the abrasion-resistant overlay is damaged and color peeling occurs

Engineering Contradiction:

Improvejoint depthVSAvoidcolor peeling and abrasion damage

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

Instead of milling after overlay application, the invention applies the overlay first and then presses the chamfer through it. This reverses the sequence of operations to avoid damaging the overlay and subsequent color layers, eliminating the problem of color peeling and abrasion damage in the joint area.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention replaces the mechanical milling process with a pressing process. Instead of removing material through milling, the chamfer is created by pressing the overlay and underlying layers, which maintains the integrity of the overlay and prevents color peeling while still achieving the desired visual depth effect.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If the overlay is applied after chamfer pressing, then the surface is protected, but the chamfer appears shallower and less visually prominent

Engineering Contradiction:

Improvesurface protectionVSAvoidchamfer visual depth

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The overlay is applied in advance before the chamfer pressing operation. This allows the overlay to be pressed together with the underlying layers, forming an integrated structure where the chamfer visual depth is achieved without compromising surface protection. The overlay maintains its protective function while the pressed chamfer creates the desired visual effect.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP4524344B1Floor panel with joint, floor panel arrangement and method for producing

Publication Date: 2025.12.17 SWISS KRONO TEC AG

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AI summary

The invention relates to a floor panel (1), wherein the floor panel comprises: - a plate-shaped core (20) with a visible printed layer (40); - an overlay (50) on the visible printed layer (40), such that the visible printed layer (40) is protected by the overlay (50); and - at least one chamfer (24) which is pressed into the plate-shaped core (20) by the overlay (50), wherein the visible printed layer (40) has an effect on a surface of the at least one chamfer (24) to enhance an optical depth effect of the chamfer (24).