Slip-Resistant Elastomer Floor Covering With Polymeric Granules
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Solution Overview
Problem
Existing floor coverings with high slip resistance, featuring roughened surfaces with hard granular particles, are difficult to cut and process due to the hardness of the materials, leading to assembly and processing challenges.
Innovation Solution
A floor covering with a base material of elastomeric material and a surface roughened with granular particles made of polymeric materials, which are softer and easier to process than mineral particles, providing high slip resistance without the processing difficulties of mineral particles like corundum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hard mineral particles (corundum, quartz, silicon carbide) are used to roughen the surface, then slip resistance is improved, but cutting and processing become difficult
Solution Approach 1:
The patent changes the material parameter of the granular particles from hard mineral materials (corundum, quartz) to polymeric materials with varying hardness. This parameter change maintains the surface roughening effect for slip resistance while dramatically improving processability and ease of cutting, as polymers are inherently easier to process than hard minerals.
Solution Approach 2:
The patent creates a composite material system combining elastomeric base material with polymeric granular particles. This composite approach allows optimization of both properties: the elastomeric base provides flexibility and comfort, while the polymeric particles provide slip resistance. The composite structure resolves the contradiction by selecting compatible materials that work together rather than compromising either function.
2Ease of manufacture
If thermoplastic polymers with low melting temperature are used, then processing becomes easier, but particles may mix with base material during production
Solution Approach 1:
The patent carefully selects thermoplastic polymers with specific melting temperature parameters that are lower than vulcanization temperature but high enough to prevent premature melting during mixing. This parameter optimization allows particles to remain stable during processing while still enabling surface floating during controlled vulcanization, resolving the contradiction between ease of processing and composition stability.
Solution Approach 2:
The patent applies preliminary action by pre-mixing the thermoplastic particles into the elastomeric base material before vulcanization. This preliminary mixing ensures uniform distribution and proper positioning of particles throughout the base material, preventing them from sinking or migrating during subsequent processing steps, while the controlled temperature profile ensures particles only melt at the appropriate stage.
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 use of polymeric granular particles achieves high slip resistance while simplifying production and processing, allowing for easy cutting and improved abrasion resistance, with specific thermoplastic polymers ensuring the particles remain on the surface during vulcanization, maintaining anti-slip properties.
Implementation Method 1
it is even desirable that the particle material melts during the vulcanization of the base material in order to float on its surface
Implementation Method 2
The melting of the particle material itself is not critical as long as the particle droplets remain as such
Implementation Method 3
After cooling, the particle droplets recrystallize back into granular particles
Data Source
AI summary
A floor covering comprises a base material substantially in sheet or tile form, made of an elastomeric material with a slip-resistant surface containing granular particles. The granular particles comprise a polymeric material having hardness significantly greater than that of the elastomeric material.