Thermoplastic Floor Panels Using Dry-Blend Powder Processing

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Solution Overview

Problem

Existing methods for manufacturing thermoplastic floor panels face challenges such as high energy consumption, material degradation, high density, limited composition variation, and difficulty in achieving homogeneous layers, particularly when using granulated materials.

Innovation Solution

A method involving the use of a dry-blend of thermoplastic material, which is strewn and consolidated without granulating, allowing for more efficient processing, reduced energy consumption, and the ability to create thinner, more homogeneous layers with improved foaming capabilities using chemical blowing agents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If extrusion process is used to form thermoplastic carrier, then continuous production is achieved, but production speed is slow and material degradation occurs

Engineering Contradiction:

Improveproduction speedVSAvoidmaterial degradation

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent changes the physical state of thermoplastic material from granulated to powder form, and modifies processing parameters by using a combination of heating and pressing operations instead of high-speed extrusion. This allows the material to be processed at lower temperatures and speeds, preventing degradation while maintaining continuous production capability through the powder's ease of handling and uniform melting characteristics.

Inventive Principle:

Principle #35Parameter changes

2Strength

If rigid thermoplastic material is extruded, then structural integrity is maintained, but friction heat increases and material degradation occurs

Engineering Contradiction:

Improvestructural integrityVSAvoidfriction heat

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The patent modifies the material form from granulated to powder, which changes the friction characteristics during processing. Powder form reduces contact area and friction heat generation during spreading and pressing operations. The material is processed at lower temperatures and pressures, maintaining structural integrity while minimizing energy loss to friction heat.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If fillers such as chalk or lime are added to thermoplastic material, then composition variability is improved, but melt viscosity increases

Engineering Contradiction:

Improvecomposition variabilityVSAvoidmelt viscosity

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The patent changes the physical state of the material from granulated to powder form, which fundamentally alters how fillers interact with the thermoplastic matrix. In powder form, fillers are more uniformly distributed and require less energy to incorporate, reducing the increase in melt viscosity. This allows for greater composition variability with lower energy input during processing.

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If granulated thermoplastic material is used, then processing flexibility is improved, but homogeneous layers are difficult to achieve

Engineering Contradiction:

Improveprocessing flexibilityVSAvoidlayer homogeneity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent changes the particle size and form of thermoplastic material from granulated to powder form. This parameter change enables superior layer homogeneity because powder particles are smaller and more uniform, allowing for more consistent distribution and melting. The powder form maintains processing flexibility while achieving the desired homogeneity that granulated materials cannot provide.

Inventive Principle:

Principle #35Parameter changes

5Shape

If calendering process is used to form floor panels, then surface smoothness is improved, but production speed is limited by high melt viscosity

Engineering Contradiction:

Improvesurface smoothnessVSAvoidproduction speed

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

The patent changes the material form from granulated to powder, which fundamentally alters the processing dynamics. Powder form materials flow more uniformly and require less pressure to achieve smooth surfaces, allowing calendering or pressing operations to proceed at higher speeds. The reduced particle size and improved flow characteristics of powder materials eliminate the speed limitations imposed by high melt viscosity that affect granulated materials.

Inventive Principle:

Principle #35Parameter changes

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

This approach results in more economical, ecologically friendly, and stable floor panels with reduced density and improved dimensional stability, while minimizing the risk of telegraphing imperfections.

Implementation Method 1

heating and pressing the strewn layers

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

heating and pressing the strewn layers

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS12448789B2Floor panel for forming a floor covering

Publication Date: 2025.10.21 UNILIN BV

AI summary

Floor panel for forming a floor covering, where the floor panel includes a carrier on the basis of a thermoplastic material and a top layer provided on the carrier. The thermoplastic material is free from plasticizers or includes a plasticizer in an amount up to maximum 20 phr, where the thermoplastic material is foamed or expanded, and where the carrier is provided with a reinforcement layer.