Skirting Board Bending Method for Floor Covering Match
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Solution Overview
Problem
Traditional skirting boards and profiled sections do not match floor coverings perfectly, suffer from durability issues due to sunlight-induced discolouration, and are costly to produce with non-identical print or structure, and are not suitable for DPL or DLP sheet materials due to their brittle top layers.
Innovation Solution
A method to manufacture skirting boards from the same sheet material as floor panels, involving a panel-shaped element with a decorative top layer and a carrier material, where recesses are filled with a different composition filler, allowing the decorative top layer to be bent continuously and hardened for strength and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional wrapping process with film/foil is used to manufacture skirting boards, then the manufacturing process is simple and cost-effective, but the print or structure never matches the floor covering perfectly and the finish is always inferior
Solution Approach 1:
The patent applies parameter changes by transitioning from a wrapping process to a bending process. The sheet material is bent at an angle of at least 90 degrees to form the skirting board, fundamentally changing the manufacturing parameter from wrapping to bending. This enables the decorative top layer to maintain its original print and structure from the floor covering, achieving perfect matching while managing the complexity through standardized bending operations.
Solution Approach 2:
The patent segments the sheet material into two functional parts: a carrier material that provides structural support and a decorative top layer that provides the visual match to the floor covering. This segmentation allows the decorative layer to be bent along with the carrier material, maintaining the print and structure continuity while achieving the required angular transformation for skirting board formation.
2Reliability
If film/foil wrapping is used for skirting boards, then production cost is reduced, but durability issues occur due to sunlight-induced discolouration and ageing
Solution Approach 1:
The patent changes the material parameter from wrapped film/foil to bent sheet material with an integrated decorative top layer. This parameter change ensures that the skirting board and floor covering share the same material composition and manufacturing process, guaranteeing identical ageing characteristics and colour stability under sunlight exposure, thereby improving reliability without significantly complicating manufacturing.
3Manufacturing precision
If DPL or DLP sheet materials are used for skirting boards, then aesthetic match with floor covering is achieved, but the brittle top layer makes traditional folding impossible
Solution Approach 1:
The patent applies curvature by bending the sheet material at an angle of at least 90 degrees instead of folding it. This curved bending approach, as opposed to sharp folding, distributes stress more evenly and prevents the brittle decorative top layer from cracking or breaking, enabling the use of DPL and DLP materials while maintaining aesthetic match with the floor covering.
Solution Approach 2:
The patent changes the manufacturing parameter from folding to bending at an angle of at least 90 degrees. This parameter change accommodates the brittle nature of the decorative top layer in DPL and DLP materials by avoiding the stress concentration associated with sharp folds, thereby enabling processability while maintaining the aesthetic integrity and perfect match with the floor covering.
4Ease of manufacture
If corners are folded sharply for skirting boards, then manufacturing is easier, but the aesthetic appeal is reduced and the top layer may break
Solution Approach 1:
The patent applies curvature by forming rounded corners with a defined radius instead of sharp folds. This curved corner design improves aesthetic appeal by matching the smooth finish of modern floor coverings and prevents the decorative top layer from breaking at the corner stress points, while the bending process remains sufficiently simple for manufacturing.
Data Source
AI summary
The present invention relates, on the one hand, to a skirting board for a wall of a space or finishing profiled section for floor covering, comprising a body composed of at least a carrier material and a decorative top layer, in which said body comprises a longitudinal part which forms at least a part of the front side of the skirting board or the finishing profiled section, and a top part which forms at least a part of the top side of the skirting board or the finishing profiled section, in which the transition (1 1) between the longitudinal part and the top part has a curved configuration, in which, at the location of said transition, some of the carrier material has been replaced by a filler having a different composition than the carrier material, and that the decorative top layer (2) is continuous at the location of the transition (1 1). On the other hand, the present invention relates to a method for manufacturing such a skirting board.