Method for producing an elastomer floor covering having a decorative layer and an elastomer floor covering with a decorative layer
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Solution Overview
Problem
Current methods for producing elastomer floor coverings with decorative layers lack flexibility in design options and often result in increased production costs and potential quality disadvantages.
Innovation Solution
A method involving a first rubber mixture, a decorative carrier material with a second rubber mixture, shaping, and vulcanizing to create a decorative layer integrated into the elastomer floor covering, allowing for various graphic designs and colors, with the option to prefabricate and store the decorative carrier material independently of the rubber sheet production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If decorative particles are embedded in the rubber sheet during production, then the decorative effect is achieved, but the production process becomes more complex and costly
Solution Approach 1:
The patent divides the floor covering into separate functional layers: a rubber sheet base layer and a decorative layer. The decorative layer is applied separately to the rubber sheet, allowing independent production and processing of each component. This segmentation simplifies the overall production process while maintaining design flexibility, as the decorative layer can be manufactured and applied as a distinct element rather than embedding particles throughout the entire rubber matrix during complex multi-step processes.
2Adaptability or versatility
If decorative layers are integrated during rubber sheet production, then design variety is achieved, but production time and costs increase
Solution Approach 1:
The decorative layer is prepared in advance as a separate component with pre-applied decorative patterns, colors, and designs. This preliminary preparation allows the decorative layer to be manufactured independently and stored ready for application. When producing the floor covering, the pre-prepared decorative layer is simply applied to the rubber sheet and vulcanized, significantly reducing production time compared to creating decorative effects during the rubber sheet formation process itself.
3Adaptability or versatility
If complex decorative structures are created during vulcanization, then aesthetic quality improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent separates the structural function (rubber sheet) from the aesthetic function (decorative layer). The decorative layer is manufactured as a separate component with its decorative patterns and structures already formed before application to the rubber sheet. This segmentation allows each layer to be optimized independently: the rubber sheet for structural properties and the decorative layer for aesthetic qualities, without the need for complex coordinated precision in a single integrated 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
This method enables an almost unlimited number of design possibilities while maintaining the beneficial properties of elastomer floor coverings, simplifying production, reducing costs, and ensuring high-quality, durable decorative layers with improved abrasion resistance.
Implementation Method 1
Vulcanizing the rubber sheet and the decorative layer applied thereon, the decorative layer bonding to the rubber sheet
Data Source
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AI summary
The invention relates to a method for producing an elastomer floor covering, comprising the following steps: providing a first rubber mixture (2); providing a supporting material for the decoration (6), which is furnished with a decorative layer (7) in certain areas, wherein the decorative layer (7) contains a second rubber mixture; forming the first rubber mixture (2) by transforming it into a flat rubber web (5); applying the supporting material for the decoration (6) provided with the decorative layer (7) onto the flat rubber web (5), wherein the decorative layer (7) comes into contact with the flat rubber web (5); vulcanizing the flat rubber web (5) with the decorative layer (7) applied to it, wherein the decorative layer (7) bonds with the flat rubber web (5); and removing the supporting material for the decoration (6). The invention further relates to an elastomer floor covering produced in this way.