Waterproof Sandwich Panel With Rigid Layers And Foam Core

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Solution Overview

Problem

Conventional wood-based and thermoplastic panels for floor and wall coverings face issues such as hygroscopicity, low durability, visible unevenness, and difficulty in assembling due to flexibility, necessitating a solution that balances waterproofness, rigidity, and ease of installation.

Innovation Solution

A sandwich-structured panel with a non-hygroscopic thermoplastic central layer, rigid top and bottom layers, and interlocking coupling means, featuring a foam structure and cellulose-based layers with oriented fibers, which provides enhanced rigidity, sound dampening, and aesthetic appeal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If wood-based materials are used for panels, then aesthetic appeal and natural appearance are improved, but hygroscopicity increases affecting lifetime and durability

Engineering Contradiction:

Improveaesthetic appealVSAvoidlifetime and durability

Core Design Contradiction:

Illumination intensityVSReliability

Solution Approach 1:

The patent applies composite materials by combining a thermoplastic central layer with rigid top and bottom layers. The rigid layers provide dimensional stability and resistance to moisture while the thermoplastic core provides waterproofing, creating a composite structure that achieves both aesthetic appeal and durability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material parameters by transitioning from hygroscopic wood-based materials to a thermoplastic-based composite with controlled moisture properties. The rigid layers are designed with specific mechanical properties (rigidity above 35 N/mm²) to prevent moisture absorption while maintaining aesthetic appearance.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If polyvinyl chloride is used for panels, then waterproof properties are improved, but flexibility increases making assembly difficult and surface durability decreases

Engineering Contradiction:

Improvewaterproof propertiesVSAvoidassembly ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent uses a composite structure where the rigid top and bottom layers provide structural stability for easy assembly with coupling means, while the thermoplastic central layer maintains waterproof properties. This composite approach eliminates the excessive flexibility issue of pure polyvinyl chloride panels.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by giving different regions of the panel different properties: the top and bottom layers are rigid for structural stability and easy assembly, while the central layer is flexible and waterproof for water resistance. This localized differentiation resolves the contradiction between waterproofing and assembly ease.

Inventive Principle:

Principle #3Local quality

3Reliability

If flexible thermoplastic material is used for panels, then waterproof properties are improved, but rigidity decreases causing visible unevenness through the panel

Engineering Contradiction:

Improvewaterproof propertiesVSAvoidsurface flatness

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The patent employs composite materials with rigid top and bottom layers that mask underlying substrate unevenness, while the thermoplastic central layer maintains waterproofing. The rigid layers act as a stable surface that does not conform to substrate irregularities, eliminating visible unevenness.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the rigidity parameter of the panel by introducing rigid layers with specified mechanical properties (rigidity above 35 N/mm²). This parameter change ensures the panel surface remains flat and does not reveal substrate unevenness, while the thermoplastic core maintains waterproof properties.

Inventive Principle:

Principle #35Parameter changes

4Ease of operation

If rigid layers are added to increase panel rigidity, then assembly ease and surface flatness are improved, but panel weight increases

Engineering Contradiction:

Improveassembly easeVSAvoidpanel weight

Core Design Contradiction:

Ease of operationVSWeight of moving object

Solution Approach 1:

The patent uses a composite structure with thin rigid layers (0.3-1.0 mm thickness) that provide sufficient rigidity for easy assembly and surface flatness. The thermoplastic central layer with foam structure provides lightweight core support, optimizing the weight-rigidity balance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies porous foam material in the central layer to reduce density and weight. The foam structure provides adequate structural support while minimizing weight, allowing rigid layers to be kept thin for assembly ease without excessive weight gain.

Inventive Principle:

Principle #31Porous materials

Data Source

PatentEP3744924B1Panel suitable for assembling a waterproof floor or wall covering, method of producing a panel

Publication Date: 2021.10.13 CHAMPION LINK INT

Figure 1~3

AI summary

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 panel having a sandwich structure which comprises a central layer basically composed of a thermoplastic material, a rigid top layer and a rigid bottom layer.