Wood Floor Panel Plastic Elevations Noise Reduction
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Solution Overview
Problem
Laminate flooring is prone to noise emission due to its lack of dimensional stability and soundproofing, which restricts its use in humid areas and multi-story buildings, and existing solutions are costly, complex, and increase product weight or create disposal issues.
Innovation Solution
A wood material panel with plastic elevations on its underside, creating a gap between the panel and the floor, which reduces noise emission through increased oscillating mass and air gap, using a hot-melt pressure-sensitive adhesive to secure the panel without significant thickness or weight addition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If soundproofing layers such as wood fiber insulation boards, rubber mats, or polyethylene foam webs are provided between the floor panels and the floor, then noise emission is reduced, but product cost and weight increase significantly
Solution Approach 1:
The soundproofing function is segmented from the separate soundproofing layers and integrated into the floor panel structure itself through the plastic elevation elements. This concentrates the soundproofing function into discrete structural features rather than requiring extensive separate layers, reducing overall weight while maintaining noise reduction effectiveness.
Solution Approach 2:
The plastic elevation elements are nested within the floor panel structure, with the adhesive material forming elevations that protrude from the underside of the panel. This nesting approach integrates the soundproofing function within the existing panel geometry, avoiding additional weight from separate soundproofing layers.
2Object-affected harmful factors
If mineral-filled insulating mats (heavy foil) are glued to the back of the floor panels, then footfall noise is reduced, but product cost and weight increase
Solution Approach 1:
The soundproofing function is segmented from the separate soundproofing layers and integrated into the floor panel structure itself through the plastic elevation elements. This concentrates the soundproofing function into discrete structural features rather than requiring extensive separate layers, reducing overall weight while maintaining noise reduction effectiveness.
3Object-affected harmful factors
If adhesive strips made of synthetic rubber are applied to the back of the laminate floor panels, then impact and room noise are reduced, but product cost increases and laying complexity increases
Solution Approach 1:
The adhesive function and the soundproofing function are merged into a single integrated component. The plastic elevation elements serve both as adhesive carriers and as soundproofing features, eliminating the need for separate adhesive strips and reducing laying complexity.
Solution Approach 2:
The plastic elevation elements perform multiple functions simultaneously: they provide adhesive bonding, create air gaps for soundproofing, and add oscillating mass for impact noise reduction. This multi-functionality simplifies the overall system and reduces laying complexity.
4Object-affected harmful factors
If the laminate floor is glued over the entire surface to the floor below, then noise emission is reduced, but the floor panel cannot be removed easily and tension build-up occurs due to dimensional changes
Solution Approach 1:
The bonding is segmented from complete surface adhesion to discrete bonding points through the plastic elevation elements. This allows the floor panel to be bonded securely for noise reduction while maintaining the ability to remove individual panels by pulling at the elevation points without requiring complete adhesion breakdown.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Significantly reduces impact and walking noise emissions while being cost-effective and eco-friendly, maintaining simplicity in installation and avoiding additional disposal problems.
Implementation Method 1
the plastic elevations serve to reduce footfall noise emissions... a vacuum is formed so that the panel can be fixed to a surface without the use of an adhesive. Furthermore, the plastic elevations serve to reduce footfall noise emissions
Implementation Method 2
using a hot-melt pressure-sensitive adhesive to secure the panel
Data Source
Figure 1~2
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AI summary
The invention relates to a wood-based panel, in particular a floor panel, with a top and a bottom having two longitudinal edges a, a' and two transverse edges b, b', wherein at least one plastic projection of a predetermined height is provided on the bottom of the wood-based panel. The invention also relates to a method for its manufacture.