Elastomer Flooring Decor Layer Bonding Through Vulcanization

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Solution Overview

Problem

Current methods for manufacturing elastomeric flooring with a decor layer lack flexibility in design and color options, and often result in increased manufacturing costs and potential quality disadvantages.

Innovation Solution

A method involving a first rubber mixture and a decor carrier material with a second rubber mixture, where the decor layer is applied and vulcanized onto the rubber web, allowing for various design and color possibilities through templates and screen printing, enabling independent manufacturing of the decor carrier material and rubber web, and ensuring a secure bond.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If decor elements are embedded in the rubber sheet, then the decor surface is formed, but the manufacturing complexity increases and design flexibility is limited

Engineering Contradiction:

Improvedesign flexibilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The flooring system is divided into separate components: a rubber base layer and a separate decor layer that can be independently manufactured and then combined. This segmentation allows each layer to be produced using optimized processes and enables flexible combination of different decor designs with various rubber bases.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The decor layer is pre-manufactured on a carrier material with various graphic designs and color patterns before being applied to the rubber base. This preliminary preparation of the decor layer allows for extensive design variations to be created in advance, which can then be easily transferred to the final flooring product.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If multiple decor variants are manufactured separately, then design variety is achieved, but manufacturing costs increase

Engineering Contradiction:

Improvedesign varietyVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

A single rubber base layer can be combined with multiple different decor layers, each carrying different graphic designs and color patterns. The standardized interface between the base layer and decor layers allows one rubber base to serve multiple design purposes, reducing the need to manufacture entirely separate flooring products for each design variant.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The decor layer is created by varying parameters such as color, pattern, and graphic design on a standardized carrier material structure. By changing these surface parameters rather than the entire structure, multiple design variants can be produced from a single manufacturing process framework, significantly reducing costs.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the decor layer is applied before vulcanization, then bonding is achieved, but the bonding strength may be insufficient

Engineering Contradiction:

Improvebonding strengthVSAvoidbonding reliability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The bonding between the decor layer and rubber base is achieved through the vulcanization process, which involves a chemical phase transition where sulfur cross-links the rubber polymer chains. This chemical bonding process creates strong, permanent bonds between the decor layer and the rubber base, ensuring reliable attachment.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The final flooring product is a composite structure consisting of the rubber base layer and the decor layer bonded together through vulcanization. The use of composite materials with different properties (elastic rubber base and decorative surface layer) allows each component to fulfill its specific function while achieving strong integration through the bonding process.

Inventive Principle:

Principle #40Composite materials

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 allows for an almost unlimited variety of graphic designs and colors, simplifies manufacturing, reduces costs, and maintains the beneficial properties of elastomeric flooring while ensuring a durable and attractive surface.

Implementation Method 1

Vulcanizing the rubber web and the decor layer applied to it, wherein the decor layer bonds to the rubber web

Methodology Applied

Scientific EffectVulcanization:

Data Source

PatentUS10300650B2Method for producing an elastomer floor covering having a decorative layer and an elastomer floor covering with a decorative layer

Publication Date: 2019.05.28 NORA SYST

AI summary

An exemplary method for manufacturing an elastomeric flooring comprises: providing a first rubber mixture (2); providing a decor carrier material (6) comprising areas with a decor layer (7) wherein the decor layer (7) contains a second rubber mixture; shaping the first rubber mixture (2) by converting it to a rubber web (5); applying the decor carrier material (6) comprising the decor layer (7) onto the rubber web (5), wherein the decor layer (7) comes in contact with the rubber web (5); vulcanizing the rubber web (5) with the decor layer (7) applied to it, wherein the decor layer (7) bonds to the rubber web (5); and removing the decor carrier material (6).