Acoustic Floor Panel With Non-Woven Textile Layer
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Solution Overview
Problem
Conventional floor coverings made from modular PVC elements lack adequate acoustic properties for sound insulation and walking comfort while maintaining mechanical stability.
Innovation Solution
A multilayer panel design featuring a non-woven textile layer with a free thickness, bonded to upper and backing layers using limited impregnation, enhances sound insulation and shock absorption by retaining air within the textile layer, while maintaining mechanical stability through a rigid backing layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a layer of reinforcing glass is embedded in the thickness of a layer of PVC to improve dimensional stability, then dimensional stability is improved, but acoustic properties deteriorate
Solution Approach 1:
The patent introduces a non-woven textile layer with controlled porosity between the upper PVC layer and the backing layer. This porous structure allows air to be trapped within the textile matrix, creating acoustic insulation that improves sound absorption and reduces impact noise transmission, thereby resolving the acoustic deterioration caused by the glass reinforcement layer.
Solution Approach 2:
The patent creates a composite structure combining PVC layers with a non-woven textile layer. This composite design integrates the mechanical stability of PVC with the acoustic benefits of the textile's fibrous structure, achieving both dimensional stability and improved acoustic properties simultaneously.
2Strength
If the non-woven textile layer is fully impregnated by bonding layers to ensure strong adhesion, then bonding strength is improved, but acoustic properties deteriorate
Solution Approach 1:
The patent applies local quality by creating different impregnation zones within the non-woven textile layer. The bonding layers are designed to impregnate only the surface regions of the textile fibers, leaving the central core of the textile layer non-impregnated and filled with air. This localized bonding approach ensures adequate adhesion strength while preserving the acoustic insulation properties of the air-filled core.
Solution Approach 2:
The patent implements partial action by limiting the impregnation depth of the bonding layers to only the outer portions of the non-woven textile layer. This partial impregnation provides sufficient bonding strength for structural integrity while leaving the majority of the textile layer's thickness free to provide acoustic insulation, thus avoiding the acoustic deterioration that would result from full impregnation.
3Object-generated harmful factors
If a multilayer structure with non-woven textile layer is introduced to improve acoustic properties, then acoustic insulation is improved, but device complexity increases
Solution Approach 1:
The non-woven textile layer serves multiple functions simultaneously: it provides acoustic insulation through its porous structure, acts as a bonding substrate for the PVC layers, and contributes to shock absorption. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in overall device complexity despite the multilayer structure.
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 panel achieves improved sound insulation and walking comfort, meeting classification standards for sound reduction and shock absorption, with reduced noise transmission and enhanced dimensional stability.
Implementation Method 1
the textile fibers are free to move in this thickness... In the free thickness, the textile fibers are not impregnated by any means used to bond the non-woven textile layer to the top and back layers
Implementation Method 2
The non-woven textile layer may in particular be linked to the back layer or to the upper layer by thermo lamination, cold bonding, hot bonding, extrusion of the back layer on the non-woven textile layer, by powdering hot melt glue or using double-sided adhesive
Data Source
Figure 1~4
AI summary
The invention concerns a multilayer panel for producing a floor covering having acoustic insulation properties, comprising, successively, a top layer providing wear resistance and decorative functions, a non-woven textile layer comprising textile fibres and a backing layer comprising at least one non-flexible layer made from a thermoplastic material, said layers being linked together to form the multilayer panel, the non-woven textile layer comprising a so-called free thickness in which the textile fibres are free and not impregnated.