Segmented Veneer Flooring Reduces Material Waste

Solution Overview

Problem

Conventional flooring materials with wood veneer generate waste due to the need for continuous lengths of veneer, leading to environmental waste and increased costs for manufacturers.

Innovation Solution

A surfacing product comprising a core with a veneer that includes a first and second elongate veneer segment and an insert segment positioned between them, allowing for efficient use of veneer lengths and reducing waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If a continuous length of wood veneer is used across the entire face of the core, then the veneer provides a uniform appearance, but shorter segments of veneer must be disposed of as waste

Engineering Contradiction:

Improveuniform appearanceVSAvoidveneer waste

Core Design Contradiction:

ShapeVSLoss of substance

Solution Approach 1:

The veneer is divided into multiple separate segments (first veneer segment, second veneer segment, and insert segment) that are positioned along the longitudinal axis of the core. This segmentation allows each segment to be independently sized and positioned, enabling the use of shorter veneer pieces without creating waste, while the collective arrangement maintains the overall continuous appearance across the core surface.

Inventive Principle:

Principle #1Segmentation

2Loss of substance

If shorter veneer segments are used, then waste is reduced, but the continuous uniform appearance may be compromised

Engineering Contradiction:

Improveveneer waste reductionVSAvoidcontinuous appearance

Core Design Contradiction:

Loss of substanceVSShape

Solution Approach 1:

An insert segment is positioned between the first and second veneer segments along the longitudinal axis. This insert segment acts as an intermediary element that bridges the gap between the two main veneer segments, creating a seamless transition that maintains the appearance of a continuous veneer surface while allowing the use of shorter individual veneer pieces that reduce waste.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If continuous veneer is sourced to cover the entire core length, then manufacturing is simplified, but costs increase due to waste disposal

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidveneer waste cost

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The veneer is divided into multiple separate segments (first veneer segment, second veneer segment, and insert segment) that are positioned along the longitudinal axis of the core. This segmentation allows each segment to be independently sized and positioned, enabling the use of shorter veneer pieces without creating waste, while the collective arrangement maintains the overall continuous appearance across the core surface.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent enables the recovery and utilization of shorter veneer segments that would otherwise be discarded as waste. By designing a structure that incorporates multiple veneer segments including an insert segment, the invention allows manufacturers to use shorter pieces of veneer effectively, thereby recovering value from material that would normally be thrown away and reducing disposal costs.

Inventive Principle:

Principle #34Discarding and recovering

Data Source

PatentUS20250116123A1Surfacing Products With Multiple Veneer Segments

Publication Date: 2025.04.10 SHAW IND GROUP INC

AI summary

A surfacing product (e.g., flooring element) can be elongate along a longitudinal axis. The surfacing product can have a core having a first surface and an opposed second surface that are spaced along a thickness axis. A veneer can be coupled to the first surface of the core. The veneer can have a first veneer segment that is elongate along the longitudinal axis, a second veneer segment that is elongate along the longitudinal axis, and an insert segment positioned between the first veneer segment and the second veneer segment along the longitudinal axis.