Bio-Based Composite Flooring with Natural Fibers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flooring products face challenges such as deforestation, high carbon footprint, and indoor air quality issues due to the use of certain woods and plastics, while also being costly and difficult to install.
Innovation Solution
The development of bio-based composite resilient flooring products with multiple layers structured in various orders, including layers of agricultural waste, bio-based resins, cellulosic materials, cork, rubber, and foams, which provide durability, sustainability, and aesthetic appeal without the need for an additional stability layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional wood flooring is used, then aesthetic appeal and stability are improved, but deforestation increases and carbon footprint worsens
Solution Approach 1:
The patent uses composite materials consisting of natural fibers (such as jute, hemp, or flax) combined with bio-based resins to create flooring that mimics the appearance and stability of traditional wood without requiring deforestation. This composite structure achieves both aesthetic appeal and environmental sustainability.
2Strength
If plastics are used in flooring products, then durability is improved, but indoor air quality deteriorates due to VOCs and carcinogenic chemicals
Solution Approach 1:
The patent changes the chemical parameters of the binding agent by replacing petroleum-based plastics with bio-based resins derived from renewable resources. This substitution maintains the durability and structural integrity of the flooring product while eliminating harmful VOCs and carcinogenic chemicals, thereby improving indoor air quality.
3Strength
If stone materials are used for flooring, then durability is improved, but cost and installation difficulty increase
Solution Approach 1:
The patent employs flexible thin film structures made from natural fibers and bio-based resins that can be easily rolled, transported, and installed over existing floors. This thin film approach provides stone-like durability and aesthetic appeal without the weight, cost, and installation complexity of actual stone materials.
4Stability of the object's composition
If an additional stability layer is added to flooring products, then stability is improved, but manufacturing cost and product height increase
Solution Approach 1:
The patent designs the natural fiber composite layers to perform multiple functions simultaneously: they provide structural stability, aesthetic appearance, and dimensional stability without requiring separate dedicated stability layers. This multi-functional design reduces manufacturing complexity and minimizes product height while maintaining enhanced stability.
Data Source
AI summary
A flooring product with improved durability, environmental sustainability, and cost competitiveness may include a plurality of layers. The plurality of layers may be structured in various orders, or layups. Each layer of the plurality of layers may have a specific thickness, weight/areal density, and/or other features, such as orientation, relative to one or more of the other layers.