WPC Floor Component with Integrated Injection-Molded Connectors
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Solution Overview
Problem
Existing flooring and cladding components face challenges in ease of production, moisture resistance, and design flexibility, with complex production processes and limited applicability to wet areas due to insufficient moisture resistance and restrictive design options.
Innovation Solution
A component with a core layer made from a mixture of plastic and lignocellulosic material, where connecting elements are injection molded in one piece with the core layer, allowing for a mass mixing ratio between 60:40 and 40:60, and featuring undercut connecting elements for enhanced tensile force and moisture resistance, enabling simpler production and greater design freedom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connecting elements are milled after the core layer is produced, then the core layer can be produced separately, but the production process becomes complex and requires additional processing steps
Solution Approach 1:
The connecting elements are integrated into the core layer production process itself. The mold includes forming elements that create the connecting elements (tongue and groove structures) directly during the injection molding of the core layer, eliminating the need for separate milling operations and simplifying the overall production process
Solution Approach 2:
The connecting elements are formed in advance during the core layer production process rather than being added later. The mold is designed with forming elements that create the tongue and groove structures before the core layer is completed, allowing subsequent assembly steps to be simplified
2Ease of operation
If traditional adhesives are used to lay plastic coverings, then the coverings can be laid, but emissions arise and dismantling requires great effort
Solution Approach 1:
The connecting elements are designed to enable self-connection of the covering components without requiring external adhesives. The tongue and groove structures allow components to lock together mechanically, providing self-service assembly that eliminates adhesive-related emissions and facilitates easy dismantling
Solution Approach 2:
The chemical bonding mechanism of adhesives is replaced with a mechanical interlocking system. The connecting elements create physical locks and grooves that join components together through mechanical force alone, eliminating the need for chemical adhesives and their associated emissions
3Reliability
If wood/plastic composite materials are used for outdoor coverings, then weather resistance is improved, but flat closed coverings cannot be realized which limits indoor hygienic use
Solution Approach 1:
The WPC material is applied locally to create connecting elements with specific geometric forms (tongue and groove structures) rather than using it as a generic filling material. This local application enables the material to serve dual purposes: providing weather resistance where exposed and enabling precise mechanical connections for indoor applications
4Strength
If connecting elements are designed with undercuts for tensile force, then the connection strength is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The geometry of the connecting elements is optimized with specific dimensional parameters. The undercuts are designed with proportions that provide sufficient tensile force while remaining compatible with standard injection molding tolerances. The forming elements in the mold are designed to create these optimized geometries reliably through conventional manufacturing processes
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
The solution simplifies production, enhances moisture resistance, and allows for more complex and flexible designs, including filigree structures, while maintaining mechanical strength and stability, making the components suitable for both dry and wet areas.
Implementation Method 1
at least the core layer is formed from a mixture comprising a plastic and a lignocellulosic material, wherein the connecting elements are injection molded in one piece with the core layer
Data Source
Figure 1~4
Figure 5A~5F
Figure 5G~5H
AI summary
The invention relates to a component, preferably for covering floors, walls and ceilings, comprising a core layer (2, 7), wherein at least the core layer (2, 7) is formed from a mixture comprising a polymer and a lignocellulose-containing material, and wherein the core layer (2, 7) is provided on at least two of its mutually opposite side edges (4, 4', 9, 13) with corresponding connection elements (3, 3', 6, 11, 14). In order to be able to provide a component which can be produced more simply, provision is made for the connection elements (3, 3', 6, 11, 14) to be injection-moulded in one piece with the core layer (2, 7).