Composite Crystal Flooring Density and Stability
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Solution Overview
Problem
Current wood-plastic flooring has low production efficiency due to complex manufacturing processes and poor thermal stability, while stone-plastic flooring has high density and transportation costs, necessitating a flooring solution with low density and improved stability.
Innovation Solution
A composite crystal flooring with a multi-layer structure, including a substrate layer composed of polyvinyl chloride, inorganic fillers, foaming agents, regulators, lubricating agents, and stabilizers, achieving a foaming density less than 1.1 g/cm³ and thermal stability through a coextrusion and foaming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wood-plastic flooring is used, then the manufacturing process is simple, but the production efficiency is low and thermal stability is poor
Solution Approach 1:
The patent uses composite materials by combining polyvinyl chloride resin with inorganic fillers (calcium carbonate, fly ash, hollow glass microbeads) and wood flour to create a flooring material that achieves both manufacturing simplicity and improved production efficiency. The composite formulation allows for better processing characteristics while maintaining thermal stability.
Solution Approach 2:
The patent introduces hollow glass microbeads as a porous filler material in the composition. These microbeads create a lightweight, porous structure that improves production efficiency by reducing material density and enhancing thermal insulation properties, while still allowing for straightforward manufacturing processes.
2Ease of manufacture
If wood-plastic flooring is used, then the manufacturing process is simple, but the thermal stability is poor causing warping and deforming
Solution Approach 1:
The patent employs composite materials combining polyvinyl chloride resin with inorganic fillers (calcium carbonate, fly ash, hollow glass microbeads) and wood flour. This composite structure provides thermal stability through the inorganic components while maintaining manufacturing simplicity, preventing warping and deforming during use.
Solution Approach 2:
The patent optimizes the compositional parameters by specifying precise weight ratios of components (40-60% inorganic fillers, 20-40% wood flour, 10-30% polyvinyl chloride resin) to achieve the desired thermal stability. This parameter control ensures dimensional stability under temperature variations while keeping the manufacturing process simple.
3Stability of the object's composition
If stone-plastic flooring is used, then the stability is better, but the density is higher and transportation cost is higher
Solution Approach 1:
The patent incorporates hollow glass microbeads as porous filler material, creating a lightweight structure with reduced density. This porous approach maintains dimensional stability and resistance to warping while significantly lowering the overall density compared to traditional stone-plastic flooring, thereby reducing transportation costs.
Solution Approach 2:
The patent substitutes expensive stone materials with more economical inorganic fillers like calcium carbonate and fly ash combined with hollow microbeads. This substitution achieves comparable stability at lower density and cost, making the flooring more economically viable for transportation and installation.
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 crystal flooring offers improved thermal stability, reduced warpage, and lower density, enhancing production efficiency and reducing transportation costs while maintaining structural integrity.
Implementation Method 1
Components of the second structural layer may include polyvinyl chloride, one or more inorganic fillers, at least one foaming agent, at least one foaming regulator
Implementation Method 2
Components of the second structural layer may include polyvinyl chloride, one or more inorganic fillers, at least one foaming agent, at least one foaming regulator, at least one lubricating agent, and at least one stabilizer
Data Source
AI summary
Embodiments of the present disclosure disclose a composite crystal flooring. The composite crystal flooring may have a multi-layer structure. The composite crystal flooring may include a substrate layer. The substrate layer may include at least a first structural layer, a second structural layer, and a third structural layer. The second structural layer may be located between the first structural layer and the third structural layer. A foaming density of the second structural layer may be less than 1.1 grams per cubic millimeter. Components of the second structural layer may include polyvinyl chloride, one or more inorganic fillers, at least one foaming agent, at least one foaming regulator, at least one lubricating agent, and at least one stabilizer. The one or more inorganic fillers may include modified fly ash, hollow glass microbeads, and composite calcium. The composite crystal flooring with a low density may have good thermal stability and rigidity.