Layered Composite Flooring Core for Impact Noise and Strength
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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 use, lacking properties 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 rigid core made of densified fiber batts of oriented fibers with different melting points, and a decorative portion affixed to the core, optionally including natural fibers and multi-component fibers, is developed to provide improved structural and aesthetic properties and methods for manufacturing such articles.
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 thermoplastic polyolefin fibers with natural fibers (such as wood, bamboo, or agricultural residues) to create a composite board that achieves both low impact noise and high radiant panel ratings. The composite structure allows the thermoplastic component to provide acoustic damping while the natural fibers contribute to thermal radiation properties and structural integrity.
Solution Approach 2:
The patent changes the physical and chemical parameters of the fiberboard by controlling fiber orientation, density distribution, and compositional ratios. Specifically, the thermoplastic polyolefin fibers are oriented in specific directions during manufacturing to optimize acoustic properties, while the overall composition is tuned to achieve both noise reduction and thermal radiation performance simultaneously.
2Strength
If complex layer structures are used for heavy duty applications, then they achieve suitable characteristics, but they increase manufacturing complexity and cost
Solution Approach 1:
The patent segments the fiber composition into distinct functional components: thermoplastic polyolefin fibers for structural strength and impact resistance, and natural fibers for additional mechanical properties and sustainability. This segmentation allows each component to be optimized for its specific function while maintaining a relatively simple overall structure.
Solution Approach 2:
The patent applies local quality by creating regions within the composite board with different fiber orientations and densities. The thermoplastic polyolefin fibers are strategically oriented in areas requiring high impact strength, while natural fibers are distributed to enhance overall structural integrity. This localized optimization achieves heavy-duty performance without requiring a complex multi-layer structure.
3Object-affected harmful factors
If fiberboards are used to reduce environmental impact, then they provide eco-friendly alternatives, but they lack sufficient impact strength and dimensional stability for heavy duty applications
Solution Approach 1:
The patent creates a composite material system that combines the environmental benefits of natural fibers with the mechanical strength of thermoplastic polyolefin fibers. The natural fibers (wood, bamboo, agricultural residues) provide eco-friendly characteristics and renewable content, while the thermoplastic polyolefin component contributes high impact strength, dimensional stability, and durability required for heavy-duty applications.
Solution Approach 2:
The patent modifies the physical parameters of the fiberboard by controlling fiber length, orientation, and bonding characteristics. The thermoplastic polyolefin fibers are processed to achieve optimal orientation and bonding with natural fibers, creating a composite structure that simultaneously delivers environmental sustainability and the mechanical performance needed for heavy-duty use.
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 layered composite achieves high impact strength, swell resistance, and improved acoustic properties, while maintaining aesthetic and aesthetic qualities, and the method of manufacturing layered composite articles with a decorative portion and aesthetic qualities.
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
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 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 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.