Waterproof Flooring Panel with Foam Core and Rigid Top Layer
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Solution Overview
Problem
Conventional wood-based and thermoplastic panels face issues with hygroscopicity, aesthetic unevenness, low scratch resistance, and installation difficulties due to flexibility, necessitating a waterproof, rigid, and lightweight solution for floor and wall coverings.
Innovation Solution
A panel design featuring a thermoplastic core layer with a foam structure and a reinforcing thermoplastic layer, combined with a rigid top layer and interlocking coupling means, utilizing materials like PVC and ABS, which provides improved acoustic properties, impact resistance, and easy assembly without adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If wood-based materials are used for panels, then aesthetic appeal and natural appearance are improved, but hygroscopicity increases leading to reduced lifetime and durability
Solution Approach 1:
The panel uses a composite structure combining a thermoplastic core layer with a reinforcing thermoplastic layer and a rigid top layer. This composite material approach provides both the desired aesthetic appearance and improved waterproof properties while eliminating hygroscopicity issues associated with wood-based materials.
2Reliability
If polyvinyl chloride is used for panels, then waterproof properties are improved, but scratch resistance decreases and surface durability is reduced
Solution Approach 1:
The panel combines thermoplastic material for waterproofing with a rigid top layer that provides enhanced scratch resistance and surface durability. The reinforcing thermoplastic layer adds structural strength while the core layer maintains waterproof properties, creating a multi-functional composite structure.
Solution Approach 2:
Different layers of the panel have different properties optimized for their specific functions: the core layer provides waterproofing, the reinforcing layer provides structural strength, and the rigid top layer provides scratch resistance. Each layer is locally optimized for its intended purpose.
3Reliability
If flexible thermoplastic panels are used, then waterproof properties are improved, but installation difficulty increases due to bending of coupling means
Solution Approach 1:
The combination of thermoplastic core layer with reinforcing thermoplastic layer creates a panel that maintains flexibility for waterproofing while the reinforcing layer provides sufficient rigidity to prevent excessive bending during installation, making the coupling means easier to assemble.
4Strength
If rigid top layer is added to panel, then scratch resistance and durability are improved, but weight increases
Solution Approach 1:
The panel uses a composite structure with a lightweight thermoplastic foam core layer combined with a thin rigid top layer and reinforcing layer. This configuration provides the necessary scratch resistance and durability while the foam core keeps the overall weight low compared to solid materials.
Solution Approach 2:
The core layer uses thermoplastic foam material which provides structural support and rigidity while being lightweight due to its porous structure. This reduces the overall panel weight while still providing the necessary mechanical properties when combined with the reinforcing and rigid top layers.
Data Source
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AI summary
The invention relates in a first aspect, to a panel suitable for assembling a waterproof floor or wall covering by interconnecting a plurality of said panels with each other, wherein the panel has a substantially planar top surface, and a substantially planar bottom surface, at least four substantially linear side edges comprising at least one pair of opposite side edges which are provided with interconnecting coupling means for interconnecting one panel within another. The invention also relates to a method of producing a panel according to the invention.