Waterproof Wood-Composite Floor Panel with Click Interlock
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Solution Overview
Problem
Ceramic tiles are difficult to install due to their hardness and brittleness, which makes profiling for click systems challenging, and existing engineered wood flooring is not waterproof, requiring additional protective layers that can be damaged, leading to costly and labor-intensive installation processes.
Innovation Solution
A prefabricated multilayer panel with a ceramic or equivalent top layer and a waterproof, wood-based support element made from a composite material including a thermosetting binder and natural fibers, allowing for click interlocking without glue or grout, and providing dimensional stability and thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ceramic tiles are used for flooring, then waterproofness and durability are improved, but installation complexity and labor cost increase due to the need for adhesive and grout
Solution Approach 1:
The patent combines the ceramic top layer with a waterproof support element into a single integrated panel structure. The support element includes coupling profiles that enable direct mechanical interlocking between panels, eliminating the need for separate adhesive and grout materials. This merging of functions (waterproofing, structural support, and interlocking mechanism) into one component resolves the contradiction by maintaining waterproofness while simplifying installation.
Solution Approach 2:
The panel is segmented into distinct functional layers: a ceramic top layer for aesthetics and wear resistance, and a separate waterproof support element with integrated coupling profiles for mechanical interlocking. This segmentation allows each layer to optimize its specific function while working together as a unified system, reducing installation complexity compared to traditional multi-component tile systems.
2Ease of operation
If ceramic tiles are profiled for click systems, then ease of installation is improved, but the hardness and brittleness of ceramic causes chipping and breakages
Solution Approach 1:
Instead of profiling the hard and brittle ceramic tile directly (which causes chipping), the patent inverts the approach by providing the click coupling profiles on the softer, more workable support element beneath the ceramic layer. The ceramic layer remains intact and unprofiled, while the support element carries the mechanical interlocking features. This inversion resolves the contradiction by enabling easy installation through profiling without damaging the ceramic's aesthetic appearance.
Solution Approach 2:
The support element acts as an intermediary between the ceramic top layer and the click coupling system. It provides a suitable material base for creating coupling profiles that can be mechanically interlocked, while the ceramic layer maintains its integrity and appearance. This intermediary layer allows the benefits of click installation without the drawbacks of profiling hard ceramic directly.
3Stability of the object's composition
If engineered wood is used for flooring, then natural appearance is improved, but waterproofness deteriorates requiring additional protective layers
Solution Approach 1:
The patent uses a composite support element made from waterproof materials (such as PVC, WPC, or SPD) that combines the structural benefits of wood-based products with superior waterproof properties. This composite material provides both the desired natural appearance and inherent waterproofness, eliminating the need for additional protective layers required by traditional engineered wood flooring.
4Reliability
If protective layers are applied to engineered wood for waterproofing, then waterproofness is improved, but the layers can be damaged affecting the entire panel
Solution Approach 1:
The waterproofing function is merged into the core structure of the support element itself rather than being applied as a separate protective layer. The support element is inherently waterproof through its material composition (PVC, WPC, or SPD), eliminating the need for additional protective coatings that could be damaged and affect the entire panel.
Data Source
AI summary
The invention relates to a panel for constructing a floor or wall covering and to a method for manufacturing such panel. The panel according to the present invention comprises at least one substantially flat support element comprising an upper surface, a lower surface, a first pair of opposed side edges and a second pair of opposed side edges, in combination with at least one decorative top layer which is affixed to the upper surface of the support element. The support element comprises wood fibers and at least one binder.