Floor Panel With Thin Transparent Layer for Edge-Wear Control
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Solution Overview
Problem
Existing floor panels, particularly laminate and vinyl-based floating floor coverings, suffer from issues such as moisture sensitivity, noise generation, reduced bending stiffness, deformability, and accelerated wear at edges due to thick transparent thermoplastic layers, which also result in a plastic-like appearance and uneven surface impressions.
Innovation Solution
A floor panel design with a transparent thermoplastic layer thickness of less than 1 millimeter, combined with a deep chamfer that extends below the print level, and a harder substrate to minimize wear and maintain transparency, while using mechanical coupling means to reduce edge pushing and improve stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thick transparent thermoplastic layer is used to provide wear resistance and form relief, then wear resistance is improved, but transparency is reduced and a plastic-like appearance is created
Solution Approach 1:
The patent changes the thickness parameter of the transparent thermoplastic layer from conventional thick (1mm or more) to thin (less than 1mm, preferably 0.1-0.5mm). This parameter change maintains wear resistance through the hard substrate while restoring transparency and eliminating the plastic-like appearance.
Solution Approach 2:
The patent creates a composite structure combining a hard substrate (providing wear resistance) with a thin transparent thermoplastic layer (providing transparency and surface smoothness). The substrate has hardness of at least 60 on the Shore D scale, while the thin thermoplastic layer ensures optical clarity and prevents plastic-like appearance.
2Strength
If a thick transparent thermoplastic layer is used to protect the surface, then wear resistance is improved, but edge wear accelerates when panels are pushed upward
Solution Approach 1:
The patent reduces the thickness of the transparent thermoplastic layer to less than 1mm, which prevents the layer from being pushed upward at the edges during installation or use. This parameter change eliminates the mechanism that causes accelerated edge wear while maintaining sufficient wear resistance through the hard substrate.
3Shape
If a soft and thick transparent layer is used above the print, then surface relief can be formed, but bending stiffness is reduced and deformability increases
Solution Approach 1:
The patent changes the thickness parameter of the transparent thermoplastic layer to less than 1mm, which maintains sufficient bending stiffness and reduces deformability. The hard substrate (hardness ≥60 Shore D) provides structural support, allowing the thin thermoplastic layer to form surface relief without compromising overall panel stability.
4Reliability
If a thin transparent thermoplastic layer is used to maintain transparency, then view on the print is improved, but wear resistance may be reduced
Solution Approach 1:
The patent creates a composite structure where a hard substrate (hardness ≥60 on Shore D scale) provides wear resistance, while a thin transparent thermoplastic layer (thickness <1mm, preferably 0.1-0.5mm) provides transparency. The combination maintains both optical clarity and mechanical durability.
Solution Approach 2:
The patent optimizes the thickness parameter of the transparent thermoplastic layer to a specific range (0.1-0.5mm) that balances transparency and wear resistance. Simultaneously, the substrate hardness is increased to at least 60 on the Shore D scale to compensate for the reduced thickness of the protective layer.
Data Source
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AI summary
Floor panel, wherein said floor panel (1) is rectangular and oblong and comprises a substrate (6) and a top layer (7) provided on said substrate; wherein said top layer is at least composed of a print (9) and a transparent thermoplastic layer (10) situated above said print, wherein said thermoplastic layer has a thickness of less than 1 millimeter, and wherein said print globally extends in a first level (N1), and comprises parts which extend below said first level (N1).