Fiber-Reinforced Stone Flooring for Crack-Resistant Lightweight Panels
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Solution Overview
Problem
Traditional flooring materials such as wood and stone are prone to deformation, warping, cracking, and require complex installation processes, making them unsuitable for DIY decoration and increasing labor and transportation costs, while existing stone flooring solutions do not adequately address these issues.
Innovation Solution
A composite floor structure comprising a thin stone layer (0.1-10 mm) bonded with a fiber layer (0.01-2 mm) using an adhesive layer, which enhances impact resistance and prevents yellowing and alkali return, allowing for lightweight, easy installation, and reduced thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional stone flooring is used, then durability and appearance are improved, but weight and installation complexity increase significantly
Solution Approach 1:
The stone flooring is divided into multiple thin layers: a stone layer (0.1-10mm thick), an adhesive layer, and a fiber reinforcement layer. This segmentation allows the heavy traditional stone to be replaced with a composite structure that maintains durability while significantly reducing weight and installation complexity.
Solution Approach 2:
The patent creates a composite flooring material by combining stone, adhesive, and fiber reinforcement layers. This composite structure provides the durability of stone while the fiber reinforcement and adhesive binding reduce overall weight and improve installation ease compared to solid traditional stone flooring.
2Shape
If traditional stone flooring is used, then aesthetic appearance is improved, but installation time and labor cost increase
Solution Approach 1:
The stone layer is pre-processed and combined with the fiber reinforcement and adhesive in a factory setting before installation. This preliminary preparation allows for quick installation on-site, reducing installation time and labor cost while maintaining aesthetic appearance.
Solution Approach 2:
By segmenting the stone into thin layers and pre-assembling the composite structure, the installation process becomes simpler and faster, reducing on-site installation time and labor requirements while preserving the aesthetic qualities of the stone surface.
3Strength
If traditional stone flooring is used, then structural strength is improved, but susceptibility to cracking and warping increases
Solution Approach 1:
The composite structure combines stone with a fiber reinforcement layer and adhesive, creating a material that maintains structural strength while the fiber reinforcement prevents cracking and warping that occur in traditional solid stone flooring.
Solution Approach 2:
The patent changes the physical parameters of the stone by reducing its thickness to 0.1-10mm and combining it with fiber reinforcement, which fundamentally alters the mechanical properties to prevent cracking and warping while maintaining necessary structural strength.
4Weight of moving object
If stone layer thickness is reduced, then weight and installation ease are improved, but impact resistance deteriorates
Solution Approach 1:
The patent compensates for the reduced stone layer thickness by incorporating a fiber reinforcement layer and adhesive, creating a composite material that maintains impact resistance despite the thinner stone layer, thereby reducing overall weight while preserving strength.
Solution Approach 2:
By changing the composition and structure of the flooring material through the addition of fiber reinforcement and adhesive, the patent maintains impact resistance even as the stone layer thickness is reduced to minimize weight.
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 composite floor provides superior impact resistance, reduces weight by over 50%, simplifies installation, and prevents yellowing and cracking, while being environmentally friendly and cost-effective.
Implementation Method 1
an adhesive layer, located beneath the stone layer
Implementation Method 2
a fiber layer, located beneath the adhesive layer... the composite floor provides superior impact resistance
Data Source
AI summary
A composite floor with a fiber layer includes: a stone layer, with a thickness between 0.1 mm and 10 mm; an adhesive layer, located beneath the stone layer; and a fiber layer, located beneath the adhesive layer, with a thickness between 0.01 mm and 2 mm. This composite floor, by compounding the stone layer and the fiber layer, has better impact resistance and excellent overall structural mechanical properties compared to traditional stone flooring, while the thickness of the wall is significantly reduced. It is lightweight, which facilitates transportation, and has super strong impact resistance, and is not prone to cracking.