Adhesive-Free Composite Flooring With Waterproof Acoustic Core

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Solution Overview

Problem

Existing flooring materials using compressed sawdust or cellulose dust as a core material are susceptible to water damage and premature failure, and the use of adhesives for layer binding leads to delamination and complex manufacturing processes, limiting production efficiency and decorative pattern flexibility.

Innovation Solution

A PVC-based flooring system with waterproof layers, UV-cured coating, and adhesive-free construction, allowing for continuous manufacturing and customizable decorative patterns, using co-extrusion and hot-melt overlaying to fuse layers without adhesives, and UV-curing for rapid coating application.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If compressed sawdust or cellulose dust is used as core material, then sound-deadening characteristic is improved, but water resistance deteriorates

Engineering Contradiction:

Improvesound-deadening characteristicVSAvoidwater damage susceptibility

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameter from compressed sawdust/cellulose dust to expanded polystyrene foam, transforming the core material's properties to achieve both sound absorption and water resistance simultaneously

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite flooring structure combining multiple layers (wear layer, decorative layer, core layer, backing layer) with different material properties to achieve both acoustic performance and water resistance

Inventive Principle:

Principle #40Composite materials

2Strength

If glue or adhesive is used to bind layers, then layer bonding strength is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvelayer bonding strengthVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent removes the adhesive layer entirely from the flooring construction, eliminating the complexity of adhesive application and curing processes while maintaining layer bonding through alternative means

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical bonding mechanism of adhesives with a mechanical interlocking system using tongue-and-groove connections and dot-and-peg fastening mechanisms

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If adhesive application and curing steps are included, then layer bonding is improved, but production efficiency deteriorates

Engineering Contradiction:

Improvelayer bondingVSAvoidcontinuous manufacturing efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent eliminates the adhesive application and curing steps from the manufacturing process, enabling true continuous production without interruptions for adhesive setting

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent incorporates bonding features directly into the layer design during manufacturing, so that layers are pre-configured for mechanical interlocking without requiring subsequent adhesive application

Inventive Principle:

Principle #10Preliminary action

4Strength

If traditional coating methods are used, then adhesion is improved, but curing time increases

Engineering Contradiction:

Improvecoating adhesionVSAvoidcuring time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent changes the coating chemistry from traditional solvent-based or water-based systems to UV-curable formulations, reducing curing time from hours to minutes while maintaining adhesion

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces chemical curing mechanisms (oxidation, moisture curing) with UV photopolymerization, enabling rapid curing through ultraviolet light exposure

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

5Productivity

If adhesive-free construction is used, then manufacturing efficiency is improved, but coating adhesion becomes problematic

Engineering Contradiction:

Improvecontinuous manufacturing capabilityVSAvoidcoating adhesion

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent applies a priming layer to the core material surface before the decorative layer, creating a surface treated in advance that ensures subsequent coating adhesion without requiring adhesives between layers

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces adhesive-based bonding with UV-cured coating systems that chemically bond to the primed surface, eliminating the need for adhesive layers while maintaining coating adhesion

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 system produces durable, efficient, and cost-effective flooring with customizable designs, eliminating water damage and delamination issues, enabling continuous production and rapid changeover between patterns.

Implementation Method 1

a UV-cured top coating

Methodology Applied

Scientific EffectUV-curing: Photopolymerisation

Data Source

PatentUS20250388005A1Glueless Dustless Composite Flooring Material System

Publication Date: 2025.12.25 I4F LICENSING NV

AI summary

A glueless dustless composite flooring material system providing PVC-based flooring having waterproof layers providing different qualities of hardness, wear-resistance, sound deadening, and decorative patterns, avoiding the use of moisture-susceptible compressed dust filler, with layers fused together, avoiding the manufacturing complexity and delamination risks of using glue or adhesive, with a quickly-cured, UV-cured top coating providing long-lasting high performance and shortening and simplifying the manufacturing, which can be done in a sheet-form, essentially continuous-run manner, with an ability to quickly and simply change the optional design printing and texturing produced, and having an optional underlayment layer.