Layered Composite Board With Densified Fiber Batt for Impact Noise
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Solution Overview
Problem
Existing laminated floors have high impact noise, low radiant panel ratings, and high environmental impact, and require complex layer structures for heavy-duty applications, lacking characteristics such as high impact strength, swell heat resistance, heat retardance, dimensional stability, and improved acoustical properties.
Innovation Solution
A layered composite article comprising a rigid backing portion with a densified fiber batt made of oriented single-component and sheath-core multi-component polyester fibers, and a decorative portion affixed to the rigid core, providing a composite board with enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional laminated floors are used, then they provide visual appeal and economic pricing, but they have high impact noise, low radiant panel ratings, and high environmental impact
Solution Approach 1:
The patent employs composite materials by combining polyester fibers with different melting points in a layered structure. The first polyester fibers (lower melting point) provide acoustic damping for impact noise reduction, while the second polyester fibers (higher melting point) provide structural integrity and heat resistance for radiant panel ratings, creating a material that simultaneously addresses both harmful factors and performance requirements
Solution Approach 2:
The invention applies local quality by creating distinct layers with different fiber compositions and properties. The lower layer uses fibers optimized for acoustic performance to reduce impact noise, while the upper layer uses fibers optimized for thermal and structural performance to achieve radiant panel ratings, allowing each region of the material to address specific performance requirements
2Strength
If complex layer structures are used for heavy duty applications, then characteristics suitable for heavy duty use are achieved, but the structure becomes complex
Solution Approach 1:
The patent merges multiple functions into a single integrated layered structure. Instead of using separate layers for different functions (acoustic damping, structural strength, heat resistance) as in traditional complex structures, the invention combines these functions into two polyester fiber layers with different melting points that work together to provide impact strength while maintaining a relatively simple structure
Solution Approach 2:
The invention uses parameter changes by varying the melting point of the polyester fibers between layers. The first polyester has a lower melting point for acoustic damping, while the second polyester has a higher melting point for structural strength, allowing the material to achieve heavy-duty characteristics through controlled parameter variation rather than structural complexity
3Object-affected harmful factors
If fiberboards are used to reduce environmental impact, then environmental friendliness improves, but they lack high impact strength, swell heat resistance, and dimensional stability
Solution Approach 1:
The patent creates a composite material system using polyester fibers that combines environmental friendliness with mechanical strength. The use of recyclable polyester materials maintains environmental benefits while the composite structure with dual-fiber composition provides the necessary impact strength, swell heat resistance, and dimensional stability that traditional fiberboards lack
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 composite board achieves high impact strength, swell heat resistance, heat retardance, dimensional stability, and improved acoustical properties, reducing the need for complex layer structures and environmental impact.
Implementation Method 1
at least one densified fiber batt, wherein the at least one densified fiber batt is comprised of a first plurality of oriented single component polyester fibers having a first melting point and a second plurality of oriented fibers being sheath-core multi-component fibers comprising a polyester having the first melting point as a core component and a polyester having a second melting point as a sheath component
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
Disclosed are layered composite articles comprising: a) a rigid backing portion comprising a rigid core having a first surface and an opposed second surface, wherein the rigid core comprises at least one densified fiber bait and wherein the at least one densified fiber batt is comprised of a first plurality of oriented fibers having a first melting point and a second plurality of oriented fibers having a second melting point different from the first melting point; and b) a decorative portion having a first surface and an opposed second surface, wherein the second surface of the decorative portion is affixed to the first surface of the rigid core. Also disclosed herein are methods of making the same.