Extruded Floor Covering Substrates for Deformation-Free Lamination
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Solution Overview
Problem
Existing methods for manufacturing floor covering products, such as vinyl tiles, face challenges in achieving high-quality lamination of films onto synthetic material-based substrates, often resulting in inaccuracies and deformations.
Innovation Solution
A method involving the formation of a single- or multi-layered substrate through extrusion, followed by laminating a continuous film using a belt press, ensuring optimal starting conditions for lamination, and utilizing isobaric pressure to achieve uniform and deformation-free lamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional lamination methods are used to attach films to substrates, then the lamination process can be completed, but inaccuracies and deformations occur in the final product
Solution Approach 1:
The substrate is pre-formed through extrusion to provide optimal starting conditions for lamination before the film is applied. This preliminary preparation ensures the substrate has the correct dimensions and surface properties needed for accurate lamination, preventing subsequent deformations
Solution Approach 2:
A belt press utilizing hydraulic or pneumatic pressure is employed to laminate the film onto the substrate. This provides uniform, controlled pressure across the entire lamination surface, ensuring consistent bonding without localized deformations or inaccuracies
2Manufacturing precision
If uniform pressure is applied during lamination, then deformation-free bonding is achieved, but the equipment complexity increases
Solution Approach 1:
A belt press with hydraulic or pneumatic actuation is used to apply uniform pressure during lamination. The fluid pressure system naturally distributes force evenly across the belt surface, achieving deformation-free bonding while using standardized, off-the-shelf hydraulic or pneumatic components rather than custom mechanical pressing mechanisms
Solution Approach 2:
The lamination process utilizes controlled changes in pressure, temperature, and time parameters. By adjusting these parameters through the belt press system, uniform lamination is achieved without requiring overly complex equipment - the same belt press can accommodate different product requirements by modifying process parameters rather than hardware
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 a high-quality, smooth, and accurately laminated floor covering product with minimal deformations, allowing for precise registration of prints and impressions, and enabling the production of various products with different thicknesses and features.
Implementation Method 1
utilizing isobaric pressure to achieve uniform and deformation-free lamination
Implementation Method 2
forming a single- or multilayered substrate by consolidating synthetic material-based starting material; the forming of the substrate is performed by means of extrusion
Data Source
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AI summary
The invention relates to a method for manufacturing a floor covering product, the method comprising the steps of - forming a single- or multilayered substrate by consolidating synthetic material-based starting material (4); - applying a print directly on the formed substrate; said print forming a decor; - applying a transparent lacquer layer; - providing impressions on the surface before or after applying said transparent lacquer layer.