Fabric Floor Tile Composite Structure for Peeling Prevention

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Solution Overview

Problem

Conventional floor tiles with fabric materials face issues such as peeling, difficulty in maintaining the natural texture and three-dimensional feeling, and poor cleaning ease, leading to reduced durability and increased contamination risks.

Innovation Solution

A floor tile design incorporating a balancing layer, anti-noise layer, functional intermediate layer, fabric material layer with thermoplastic resin fibers, and a surface coating layer, which enhances adhesion, mechanical properties, and cleaning ease while protecting the fabric material from external damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If a fabric layer is applied to floor tiles to provide texture and three-dimensional feeling, then the visual design and surface texture are improved, but the fabric layer is easily peeled off and durability is reduced

Engineering Contradiction:

Improvesurface textureVSAvoidpeeling resistance

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent applies composite materials by combining fabric material with thermoplastic resin fibers to create a layered structure. The fabric layer is impregnated with molten thermoplastic resin and bonded to a backing layer, forming a composite structure that maintains the fabric's texture while preventing peeling through strong adhesion between layers.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the physical state of the thermoplastic resin from solid to molten state during processing. The resin is heated to melt and impregnate the fabric, then cooled to solidify and bond the layers together. This parameter change enables strong adhesion while preserving the fabric's surface characteristics.

Inventive Principle:

Principle #35Parameter changes

2Shape

If the fabric surface is exposed upward to maintain natural texture, then the three-dimensional feeling is preserved, but the fabric is damaged during use and cleaning ease is reduced

Engineering Contradiction:

Improvethree-dimensional feelingVSAvoiddamage and contamination

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

The patent uses a thermoplastic resin coating layer as a protective film over the fabric surface. This thin film layer protects the fabric from damage and contamination while being thin enough to preserve the fabric's texture and three-dimensional feeling. The coating acts as a flexible protective shell.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The composite structure combines the aesthetic fabric layer with a protective thermoplastic resin layer. This multi-layer composite provides both the desired visual texture and protection against harmful factors like damage and contamination, resolving the contradiction between exposure and protection.

Inventive Principle:

Principle #40Composite materials

3Productivity

If conventional PVC-based floor tiles are used with printed layers, then production is efficient, but the characteristic surface texture of fabric material cannot be retained

Engineering Contradiction:

Improveproduction efficiencyVSAvoidfabric texture

Core Design Contradiction:

ProductivityVSShape

Solution Approach 1:

Instead of printing fabric patterns on PVC, the patent uses actual fabric material as the surface layer. The fabric's natural texture is physically present rather than copied through printing, providing authentic fabric characteristics while maintaining production efficiency through standardized manufacturing processes.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent creates a composite floor tile where the fabric layer is impregnated with thermoplastic resin and bonded to a backing layer. This composite structure allows the fabric's characteristic texture to be retained while providing the durability and production efficiency of conventional floor tiles.

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

The solution effectively prevents peeling of the fabric material layer, maintains the natural texture and three-dimensional feeling, and improves cleaning ease and durability, ensuring enhanced tensile strength and resistance to contamination.

Implementation Method 1

a fabric material layer including a thermoplastic resin fiber coated with a polymer resin

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

a surface coating layer configured to protect the fabric material layer from external damage

Methodology Applied

Scientific EffectPhysical barrier protection: Physical Containment

Data Source

PatentUS11536036B2Floor tile including fabric material and manufacturing method thereof

Publication Date: 2022.12.27 NOX CORP

AI summary

The present invention relates to: a floor tile including a fabric material, and comprising a balancing layer, a noise prevention layer, a functional sheet layer, a fabric material layer, and a surface coating layer; and a manufacturing method thereof and more specifically to a floor tile including a fabric material and a manufacturing method thereof, the floor tile being a functional tile having a natural texture and a three-dimensional effect possessed by the fabric material, having excellent durability, preventing delamination of the fabric material layer, exhibiting excellent mechanical properties such as tensile strength, and enhancing cleaning facilitation.