Co-Extruded SPC Foam Flooring for Lower Weight and Sound Absorption
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Solution Overview
Problem
Traditional SPC flooring has a high density, leading to increased weight and transportation costs, and there is a need for improved load-bearing performance in high-rise home and commercial decoration.
Innovation Solution
A co-extrusion SPC foam flooring with a stone-plastic base material structure comprising a first and second stable layer, a foaming layer in between, and a decorative and protective structure, where the foaming layer reduces the overall density to 1.4 to 1.6 g/cm3, enhancing dimensional stability and sound absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional SPC flooring with high density is used, then load-bearing performance is improved, but weight per unit area increases
Solution Approach 1:
The flooring is segmented into three distinct layers: a first stable layer (1-5mm), a foaming layer (2-10mm), and a second stable layer (1-5mm). This segmentation allows the dense stable layers to provide load-bearing capacity while the lightweight foaming layer reduces overall weight, achieving a balance between strength and weight reduction of 20-30%.
Solution Approach 2:
The invention uses composite material structure combining PVC resin (100 parts by weight) with filler powder (200-300 parts by weight) to create layers with different density characteristics. The stable layers use this composite to maintain strength while the foamed composite structure provides weight reduction.
2Strength
If traditional SPC flooring with high density is used, then structural strength is maintained, but transportation costs increase
Solution Approach 1:
By segmenting the flooring into stable layers and a foaming layer, the structure maintains structural strength through the dense stable layers while the lightweight foaming layer reduces overall density to 1.4-1.6g/cm³, directly lowering transportation costs by 20-30%.
3Weight of moving object
If density is reduced to lower weight, then transportation costs decrease, but dimensional stability may worsen
Solution Approach 1:
The segmentation into stable layers and foaming layer is key: the stable layers (1-5mm each) with dense PVC-resin-filler composite maintain dimensional stability, while the intermediate foaming layer (2-10mm) provides the weight reduction. This layered segmentation ensures that weight reduction does not compromise dimensional stability.
Solution Approach 2:
Different regions of the flooring have different densities tailored to their functions: the stable layers have high density for dimensional stability and load-bearing, while the foaming layer has low density for weight reduction. This local quality differentiation resolves the contradiction between weight and stability.
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 SPC foam flooring achieves a significant reduction in density, maintaining surface strength and improving dimensional stability while enhancing sound absorption.
Implementation Method 1
the foaming layer has a thickness in the range of 2 to 10 mm; the density of the SPC foam flooring is in the range of 1.4 to 1.6 g/cm3
Data Source
AI summary
A foam flooring includes a stone-plastic base material structure, which sequentially comprises, from top to bottom, a first stable layer, a foaming layer and a second stable layer. The first stable layer and the second stable layer are both sheets with a PVC resin and filler powder as main components, with 25-40 parts by mass of the PVC resin and 55-75 parts by mass of the filler powder; and the density of the SPC foam flooring is 1.4-1.6 g/cm3. The foaming layer is arranged between the two stable layers, such that the overall density of the flooring is significantly reduced and reaches 1.4-1.6 g/m3; since the foaming layer is arranged inside, the surface strength of the overall flooring is not influenced.