Co-foamed PVC Layer for Flooring via Sequential Foaming
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Solution Overview
Problem
Conventional sheet vinyl flooring products require multiple layers for construction, including an impregnation layer, decor layer, wear layer, and backing layer, which complicates the manufacturing process and increases costs due to the need for multiple coating steps and equipment.
Innovation Solution
A co-foamable vinyl or PVC plastisol composition that undergoes sequential mechanical and chemical foaming, allowing for a single co-foamed layer to replace multiple traditional layers, reducing the number of coating steps and equipment required while maintaining functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layers are used for construction (impregnation layer, decor layer, wear layer, backing layer), then the functional requirements are met, but the manufacturing process becomes complicated and costs increase
Solution Approach 1:
The patent combines multiple functional layers (impregnation layer, decor layer, and backing layer) into a single co-foamed plastisol layer. This layer is applied as one coating that simultaneously provides impregnation of the substrate, decorative surface, and cushioning properties through chemical foaming, thereby reducing manufacturing complexity while maintaining all necessary functions
Solution Approach 2:
The single co-foamed plastisol layer is designed to perform multiple functions simultaneously: it acts as an impregnation layer that saturates the substrate, as a decor layer that provides the visible surface, and as a backing layer that provides cushioning. This multi-functional approach eliminates the need for separate layers and simplifies the manufacturing process
2Reliability
If multiple coating steps are used to apply different layers, then the functional layers are properly formed, but the number of equipment and overhead costs increase
Solution Approach 1:
The patent merges multiple coating operations into a single coating step where one plastisol composition is applied and then processed to form all functional layers. This eliminates the need for multiple coating equipment and reduces overhead costs associated with operating and maintaining separate coating lines
Solution Approach 2:
The patent uses parameter changes during processing to achieve different layer functions from a single coating. By controlling temperature and chemical reactions during curing, the single plastisol layer transforms to provide impregnation, decoration, and cushioning properties that traditionally required multiple separate coatings
3Device complexity
If a single co-foamed layer is used to replace multiple layers, then the manufacturing process is simplified and costs are reduced, but the ability to achieve various surface finishes may be limited
Solution Approach 1:
The patent incorporates foam inhibitors at specific locations within the single plastisol layer to create localized variations in foam density and surface texture. This allows different regions of the same layer to have different properties, enabling wood-like finishes and other textured surfaces while maintaining the simplified single-layer manufacturing process
Solution Approach 2:
The plastisol composition uses a composite formulation combining PVC resin, plasticizers, foam agents, and foam inhibitors in specific ratios. This composite material structure allows the single layer to exhibit multiple characteristics including cushioning from foam, decoration from the base composition, and varied surface finishes from localized inhibitor effects
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 co-foamed layer simplifies the manufacturing process, reduces material usage and overhead costs, and allows for a variety of surface finishes, including wood-like finishes, while maintaining the necessary cushion and decorative properties.
Implementation Method 1
The co-foaming is preferably a sequential foaming of a single layer such as a single coated layer, such as sequentially applied mechanical foaming or frothing followed by chemical foaming
Implementation Method 2
This layer includes a chemical foaming agent to form a top foam
Implementation Method 3
The co-foamed layer can be a gelled froth co-foamed with a chemical foam
Data Source
AI summary
A co-foamable vinyl plastisol composition, a gelled or fused co-foamed vinyl layer, a co-foamed vinyl layer, methods of manufacture of the layer and use of the layer in floor coverings such as sheet vinyl, cushioned vinyl flooring, floor tiles, and laminated planks are described. The co-foaming is preferably a sequential foaming of a single layer such as a single coated layer, such as sequentially applied mechanical foaming or frothing followed by chemical foaming. A co-foamable vinyl plastisol composition is mechanically foamed/frothed before it is applied to a substrate. Once on the substrate, the co-foamable layer can be processed further and is chemically foamed in a later process step.