Biomass Molded Floor Manufacturing via Density Control
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Solution Overview
Problem
Conventional wood-plastic composite (WPC) floors have poor resistance to deformation and high rebound rates, leading to complex processing and low efficiency, which affects both processing and appearance.
Innovation Solution
A method for manufacturing biomass molded floors involves preparing PVC and wood-plastic boards with specific compositions and densities, bonding them with an adhesive, and molding under controlled temperature and pressure conditions to form large, concave arc-shaped panels, simplifying the process and reducing rebound.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional WPC floor molding is used, then the floor can be manufactured, but the rebound rate is high causing poor deformation resistance and affecting appearance quality
Solution Approach 1:
The patent applies parameter changes by optimizing the density of the wood-plastic board to a specific range (0.87-0.90 g/cm³) and controlling molding parameters (temperature 35-40°C, pressure 10-12 MPa, time 50-60 s) to reduce rebound rate and improve deformation resistance while maintaining manufacturing precision
Solution Approach 2:
The patent uses composite materials by combining PVC board with wood-plastic composite board of specific density composition, creating a layered structure that reduces rebound and improves overall deformation resistance of the molded floor
2Manufacturing precision
If small plate molding (190 mm×1200-1800 mm) is adopted to avoid rebound impact, then appearance quality is maintained, but the process becomes complex and processing efficiency decreases
Solution Approach 1:
The patent enables large board molding by changing the density parameter of the wood-plastic board to a optimized range (0.87-0.90 g/cm³), which allows manufacturing of larger panels (1000 mm×1200 mm-1000 mm×1800 mm) with controlled rebound, thereby simplifying the process and improving processing efficiency while maintaining appearance quality
3Productivity
If large board molding is implemented, then processing efficiency is improved and process is simplified, but rebound control becomes more difficult affecting appearance quality
Solution Approach 1:
The patent achieves both large board molding and appearance quality by optimizing multiple parameters simultaneously: wood-plastic board density (0.87-0.90 g/cm³), molding temperature (35-40°C), molding pressure (10-12 MPa), and molding time (50-60 s), creating a balanced parameter set that enables efficient large-scale production with controlled rebound
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
This method effectively reduces rebound, simplifies the manufacturing process, and improves the appearance and service life of the biomass molded floors by controlling density and molding parameters.
Implementation Method 1
coating an upper surface of the wood-plastic board with an adhesive, bonding the wood-plastic board with the PVC board
Implementation Method 2
performing molding after bonding, wherein parameters of the molding are: temperature in a range of 35−40° C., pressure in a range of 10-12 MPa
Data Source
AI summary
A method for manufacturing a biomass molded floor includes steps of: (1) preparing a PVC (polyvinyl chloride) board and a wood-plastic board, wherein a density of the wood-plastic board is in a range of 0.87-0.90 g/cm3; (2) coating an upper surface of the wood-plastic board with an adhesive, bonding the wood-plastic board with the PVC board, wherein an area of the wood-plastic board is in a range of 1000 mm×1200 mm-1000 mm×1800 mm; and (3) performing molding after bonding, wherein parameters of the molding are: temperature in a range of 35-40° C., pressure in a range of 10-12 MPa, time in a range of 50-60 s.