Layered Composite Flooring Core for Noise and Heat Resistance
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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 fibers having different melting points and a decorative portion affixed to the rigid core, which can include natural fibers and multi-component fibers, is developed to enhance structural integrity and acoustic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional laminated floors are used, then they provide visual appeal and ease of installation, but they have high impact noise, low radiant panel ratings, and high environmental impact
Solution Approach 1:
The patent employs a composite core structure combining densified fiberboard with thermoplastic resin-coated fibers. The fiberboard provides structural rigidity and acoustic damping, while the thermoplastic coating enhances heat resistance and dimensional stability. This composite approach resolves the contradiction by achieving both noise reduction and improved radiant panel ratings through material synergy.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the core material by densifying the fiberboard structure and incorporating thermoplastic resins with specific melting points. These parameter changes enable the material to simultaneously achieve acoustic damping properties for noise reduction and thermal stability for improved radiant panel performance.
2Strength
If complex layer structures are used for heavy duty applications, then characteristics such as high impact strength and dimensional stability are achieved, but the structure becomes complex and manufacturing becomes difficult
Solution Approach 1:
The patent merges multiple functional layers into a single integrated densified fiberboard structure. The thermoplastic resin is impregnated throughout the fiberboard matrix, combining structural reinforcement, impact resistance, and dimensional stability functions in one homogeneous material system, eliminating the need for separate complex layers.
Solution Approach 2:
The integration of thermoplastic resin-coated fibers within the densified fiberboard creates a composite material that inherently provides high impact strength and dimensional stability without requiring additional protective layers or complex structural arrangements.
3Temperature
If traditional fiberboards are used, then they provide basic structural support, but they lack sufficient heat resistance and swell resistance
Solution Approach 1:
The patent changes the thermal and dimensional parameters of the fiberboard by incorporating thermoplastic resins with controlled melting points and crosslinking characteristics. These parameter modifications enable the material to resist thermal degradation and swelling while maintaining structural integrity under elevated temperature and moisture conditions.
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 article achieves improved impact strength, heat resistance, dimensional stability, and acoustical properties, reducing noise and environmental impact while eliminating the need for complex layer structures.
Implementation Method 1
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
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
Disclosed are layered composite articles comprising: a) a rigid backing portion comprising a needle punched rigid core having a first surface and an opposed second surface, wherein the rigid core comprises at least one densified fiber batt 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 comprising a polyester, polypropylene, polyethylene, polyamides, polyurethane, polylactic acid, acetal, co-polyester, co-polyamide, polystyrene, or a combination thereof having a second melting point, wherein the first melting point is different from the second melting point, wherein the first plurality of oriented fibers and the second plurality of oriented fibers each have a substantially random orientation, a substantially uniform orientation, or any variation of a predetermined orientation that is between a random and uniform orientation; and b) a decorative portion having a first surface and an opposed second surface, wherein the opposed second surface of the decorative portion is affixed to the first surface of the rigid core.