Fiber Core Multilayer Flooring Rigidity and Insulation
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Solution Overview
Problem
Multilayer flooring made with traditional core materials like WPC, SPC, PVC, plywood, MDF, or HDF is heavy, provides minimal sound reduction and thermal insulation, and lacks rigidity, while these materials have increased in cost and decreased in availability.
Innovation Solution
A multilayer flooring with a core layer made of substrate fibers bound by thermoplastic binder fibers, including bicomponent fibers, which improves rigidity, sound reduction, and thermal insulation, and can be made from recycled materials that are lighter and more cost-effective.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional core materials (WPC, SPC, PVC, plywood, MDF, HDF) are used, then the flooring provides structural stability, but it becomes heavy and provides minimal sound reduction and thermal insulation
Solution Approach 1:
The patent applies composite materials by combining wood fibers, plastic particles, and binding agents to create a WPC core layer that achieves optimal balance between weight, stability, and insulation properties. This composite approach allows the flooring to maintain structural integrity while reducing density compared to traditional solid wood or dense engineered wood products.
2Stability of the object's composition
If traditional core materials (WPC, SPC, PVC, plywood, MDF, HDF) are used, then the flooring provides structural stability, but it provides minimal sound reduction and thermal insulation
Solution Approach 1:
The patent applies local quality by creating a core layer with specific local properties - the WPC composite material provides different characteristics in different aspects: structural stability for support, while the porous composite structure provides sound absorption and thermal insulation. The binding agents and fiber-plastic matrix create localized zones that trap sound waves and reduce heat transfer.
3Stability of the object's composition
If traditional core materials (WPC, SPC, PVC, plywood, MDF, HDF) are used, then the flooring provides structural stability, but it may not be as rigid as desired
Solution Approach 1:
The patent applies parameter changes by carefully controlling the composition ratios of wood fibers to plastic particles, adjusting the binding agent content, and optimizing the density of the WPC core layer. These parameter adjustments allow the flooring to achieve enhanced rigidity and dimensional stability while maintaining the benefits of composite material construction.
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 fiber core layer enhances the flooring's rigidity, sound reduction, and thermal insulation, while being lighter and potentially more affordable, with the added benefit of being 100% recyclable, thus addressing the limitations of traditional core materials.
Implementation Method 1
The thermoplastic binder fiber includes a bicomponent fiber
Data Source
AI summary
A multilayer flooring includes a decorative layer and a core layer. The decorative layer is configured to provide a desired appearance of the multilayer flooring. The core layer is disposed below the decorative layer and is configured to provide stability. The core layer is made of a substrate fiber bound together by a thermoplastic binder fiber. The substrate fiber includes cellulose fiber and/or synthetic fiber. The thermoplastic binder fiber includes a bicomponent fiber.