Composite PET Floorboard for Flexibility and Dimensional Stability
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Solution Overview
Problem
Existing PET floorboards are limited in application and fail to effectively solve the problem of flexibility, requiring locking mechanisms and being unsuitable for non-flat surfaces, and they do not meet the ASTM F137-08 flexibility test due to their hardness and toughness.
Innovation Solution
A PET floorboard made from semi-hard material with a density of 700-1000 kg/m3, processed with bevel edges for glue installation, and comprising layers such as PET felt, a UV layer, and a wear-resistant layer, and a glass fiber layer, and a floor mat layer, with heat and cold-pressing steps to ensure dimensional stability and improve the efficacy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If hard PET high-density plate is used, then dimensional stability is improved, but flexibility deteriorates
Solution Approach 1:
The patent uses a composite structure combining PET high-density plate (for dimensional stability) with PET felt (for flexibility). The PET felt layer has density of 700-1000 kg/m³ and provides the necessary flexibility and cushioning, while the hard PET plate layer maintains dimensional stability. This composite approach allows the floorboard to pass the ASTM F137-08 flexibility test while maintaining structural integrity.
Solution Approach 2:
The patent changes the density parameter of the PET material from conventional high-density (1800-2200 kg/m³) to semi-hard density (700-1000 kg/m³). This parameter change transforms the material properties to achieve both flexibility and dimensional stability, enabling the floorboard to be installed on non-flat surfaces while maintaining structural integrity.
2Adaptability or versatility
If PET felt with controlled density is used, then flexibility is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent specifies a controlled density range for PET felt (700-1000 kg/m³) and uses hot-pressing technology with customized molds to achieve uniform density distribution. The hot-pressing process applies controlled temperature and pressure to ensure consistent density throughout the PET felt panel, maintaining manufacturing precision while preserving flexibility.
Solution Approach 2:
The patent applies different density characteristics to different layers of the composite structure. The PET felt layer uses semi-hard density (700-1000 kg/m³) for flexibility, while the hard PET plate layer uses high-density (1800-2200 kg/m³) for dimensional stability. This local quality differentiation allows each layer to perform its specific function optimally.
3Reliability
If multiple layers are combined, then functional performance is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functional layers into a single integrated composite structure. The PET felt layer, hard PET plate layer, and adhesive layers are combined in a multi-layer configuration where each layer contributes specific functionality. This merging approach improves overall functional performance (flexibility, dimensional stability, hygiene) while managing complexity through systematic integration of layers.
Solution Approach 2:
The patent segments the floorboard into distinct functional layers: PET felt layer (for flexibility and cushioning), hard PET plate layer (for dimensional stability), and adhesive layers (for bonding). This segmentation allows each layer to be optimized for its specific function while maintaining overall structural integrity and simplifying the manufacturing process.
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 PET floorboard achieves flexibility, allowing installation on non-flat surfaces, passing the ASTM F137-08 test, and maintaining PET's hygiene, recyclability, and dimensional stability.
Implementation Method 1
The PET fibers are hot-pressed and preset by using a customized mold based on the requirements of finished products
Implementation Method 2
hot-melt compounding a printing layer and a wear-resistant layer to obtain a composite layer
Implementation Method 3
performing hot-pressing for fusion attachment
Implementation Method 4
cold-pressing for shaping
Implementation Method 5
coating at least one ultra-violet ray (UV) paint layer on the surface of the wear-resistant layer
Data Source
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AI summary
A method for preparing a PET floorboard comprises: hot-melt compounding a printing layer and a wear-resistant layer to obtain a composite layer; providing at least one PET felt panel on the backside of the printing layer of the composite layer, and then performing hot-pressing for fusion attachment and cold-pressing for shaping to obtain a composite panel; coating at least one UV paint layer on the surface of the wear-resistant layer of the composite panel, and then cutting into required sizes and processing edges to obtain the PET floorboard. The PET floorboard provided by the invention has such good flexibility that it will not crack or be defaced when being folded in half around a metal shaft with a diameter of 12.7 mm. Moreover, the PET floorboard is light, has a density of only 700-1000 kg/m3, and has excellent dimensional stability against high and low temperatures and safety.