Continuous Floor Covering Lamination for Precise Layer Thickness
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Solution Overview
Problem
Existing methods for manufacturing floor coverings using polymer materials, such as polyvinyl chloride, face challenges in achieving regular layer thickness and efficient production due to uncertain reinforcement positioning, leading to balancing issues and increased manufacturing costs.
Innovation Solution
A continuous manufacturing process using calenders or flat die extruders to produce and hot roll layers with a reinforcement armature, ensuring homogeneous temperature and precise layer thickness, eliminating the need for granule pressing and subsequent sanding steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pressed thermoplastic granules are used to manufacture floor coverings, then the manufacturing process can be simplified, but the layer thickness cannot be guaranteed to be regular enough (less than 0.1 mm tolerance)
Solution Approach 1:
The invention changes the physical state parameter of the thermoplastic material from granules to a more processed state (pre-formed layers or sheets), enabling better thickness control while maintaining the simplicity of the pressing operation. This parameter change allows the material to be deposited with precise thickness before pressing, resolving the contradiction between ease of manufacture and manufacturing precision.
2Productivity
If a single or double-belt press is used for continuous manufacturing, then production speed can be increased, but the maximum speed is limited by the press length regardless of coating thickness
Solution Approach 1:
The invention segments the manufacturing process into distinct stages: material deposition, drying/curing, and pressing. By separating these operations and allowing them to occur in sequence rather than simultaneously in a single long press, the production speed is no longer constrained by press length. Each stage can be optimized independently, enabling higher overall productivity without increasing device complexity.
3Loss of substance
If reinforcement positioning is uncertain in pressed granule processes, then material loss increases due to required sanding steps, but using precise positioning methods increases manufacturing complexity
Solution Approach 1:
The invention performs preliminary action by pre-forming the thermoplastic material into layers or sheets with controlled thickness before the pressing operation. This preliminary preparation ensures that the reinforcement layer is positioned at the correct depth from the start, eliminating the need for subsequent sanding to correct thickness variations. The preliminary structuring of material reduces device complexity while minimizing material loss.
4Use of energy by moving object
If granule pressing is used to bind layers together, then energy-intensive heating and cooling steps are required, but alternative methods may not achieve sufficient bonding
Solution Approach 1:
The invention replaces the traditional thermal-mechanical bonding process (heating granules to melt and press) with a direct mechanical pressing operation on pre-formed layers. The layers are deposited in a structured state that allows them to be bound together through mechanical pressure alone, substituting the thermal field with a mechanical field. This reduces energy consumption while maintaining bonding strength.
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 process guarantees precise layer thickness control, reduces material loss, and lowers production costs by optimizing reinforcement impregnation and eliminating the need for energy-intensive heating and cooling steps, while maintaining dimensional stability and reducing curvature issues.
Implementation Method 1
continuously producing and moving towards lamination means a first layer of a material comprising at least one plastic material by means of a first calender with at least two rolls
Implementation Method 2
continuously producing and moving towards lamination means a first layer of a material comprising at least one plastic material
Implementation Method 3
hot rolling together at least the first layer, the first reinforcement, and the second layer superimposed in this order
Implementation Method 4
hot laminated together with at least the first layer (1), the first reinforcement (3), and the second layer (2) superimposed in this order, to link them
Implementation Method 5
eliminating the need for energy-intensive heating and cooling steps, while maintaining dimensional stability
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method for the continuous manufacture of a floor covering, comprising at least steps consisting in: - continuously producing and moving towards lamination means (22, 24) a first layer (1) of a material comprising at least one plastic material by means of a first calender (10) with at least two rolls (14, 16); - continuously producing and moving towards the lamination means (22, 24) a second layer (2) of a material comprising at least one plastic material by means of a second calender (20) with at least two rolls (24 , 26); - scrolling towards the lamination means (22, 24) a first reinforcement reinforcement (3); - hot rolling together at least the first layer (1), the first reinforcement (3), and the second layer (2) superimposed in this order to bind them and form the floor covering.