Undulated Edge Panels for Seamless Wood Plank Illusion

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Solution Overview

Problem

Existing panel systems for floor, wall, and ceiling coverings that mimic organic wood planks suffer from a strict, inorganic appearance due to straight edges, and existing solutions like bevels or matching panel systems are costly, logistically complex, and aesthetically limited.

Innovation Solution

A rectangular panel design featuring a specially undulated edge line along its long sides, created using a combination of printed and embossed elements with varying gloss grades, which diverges from the physical edges to create an optical illusion of long, uninterrupted planks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If straight edges are used for panel connections, then the joining system works reliably, but the appearance becomes strict and inorganic

Engineering Contradiction:

Improvejoining system reliabilityVSAvoidedge appearance

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The patent applies different edge treatments to different parts of the panel: the physical connection edges remain straight for reliable joining, while the visible surface edges are made undulated to create an organic appearance. This local differentiation resolves the contradiction between connection reliability and aesthetic appearance.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent creates an optical copy of the edge line that diverges from the physical edge. The undulated edge line is printed or embossed on the decorative surface to mimic the appearance of natural wood grain patterns, while the actual physical edge remains straight for proper connection.

Inventive Principle:

Principle #26Copying

2Shape

If bevels are added to create irregular edges, then the appearance improves, but manufacturing cost increases and moisture resistance worsens

Engineering Contradiction:

Improveedge irregularityVSAvoidmanufacturing cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

Instead of physically creating irregular edges through beveling, the patent uses printed or embossed undulated edge lines on the decorative surface to copy the appearance of irregular edges. This avoids the high manufacturing costs and moisture vulnerability associated with actual physical bevels.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the mechanical process of milling bevels with a printing or embossing process. This substitution eliminates the need for material removal, reduces manufacturing complexity, and maintains moisture resistance while achieving the desired visual effect.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Shape

If matching panel sets are used to create undulating edges, then the aesthetic appearance improves, but logistical complexity and waste increase

Engineering Contradiction:

Improveundulated edge appearanceVSAvoidlogistical complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The patent makes all panels in a package identical with the same undulated edge line design, allowing any panel to connect with any other panel from the same package. This universal design eliminates the need for matching sets, simplifying logistics and reducing waste from discarded non-matching panels.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The undulated edge line is segmented across multiple panels, where each panel contributes a portion of the overall undulated pattern. This segmentation allows individual panels to be installed independently while collectively creating the appearance of continuous undulating edges across the entire surface.

Inventive Principle:

Principle #1Segmentation

4Length of moving object

If panel length is limited for transport, then transportation is easier, but the illusion of long planks is reduced

Engineering Contradiction:

Improvepanel transportabilityVSAvoidplank length illusion

Core Design Contradiction:

Length of moving objectVSShape

Solution Approach 1:

The patent uses the two-dimensional decorative surface to create the illusion of extended three-dimensional plank length. The undulated edge lines and grain patterns are designed to visually extend beyond the physical panel boundaries, creating the perception of longer planks without actually increasing panel dimensions for transport.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent uses printed or embossed patterns that copy the appearance of continuous long plank features, including grain lines and edge variations, across the panel surface. These optical copies create the illusion of extended length while the actual panels remain transportable sizes.

Inventive Principle:

Principle #26Copying

Data Source

PatentUS11280095B2Panels imitating organic wood planks comprising specially decorated edges

Publication Date: 2022.03.22 LIGNUM TECH AG

AI summary

A rectangular panel for floor-, wall- or ceiling coverings is provided comprising a visible decorative side, wherein the decorative side comprises at least one undulated edge line, which extends along the long side edges of the panel, said undulated edge line having a different design than the rest of the decorative side. In the provided panel(s), the physical edges and the optical edges may diverge, which provides the possibility that multiple panels can be installed as floor ceiling or wall covering in a way that the physical edges in a corresponding covering become almost invisible whereas the optical edges (i.e. the undulated edge lines) are perceived as artificial optical edge of virtual panels forming the covering.