Patterned Floor Covering Mixing Control
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Solution Overview
Problem
Existing methods for producing patterned floor coverings, such as marbled and moiré designs, do not achieve an optimal optical design and are not wear-resistant, leading to visibility of dirt and wear.
Innovation Solution
A multi-stage process involving miscible components with different base colors, where intermediate products are mixed to create areas with primary colors and mixed colors, ensuring a visually appealing and durable floor covering with fine color gradations, using extruders and calendering to achieve a marbled appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple differently colored components are completely mixed together, then a uniform color is achieved, but the attractive marbled pattern and fine color gradations are lost
Solution Approach 1:
The patent applies local quality by creating different mixing degrees in different regions of the floor covering. Some areas have complete mixing producing uniform colors, while other areas have partial mixing preserving color gradients and transitions. This spatial variation in mixing quality creates the attractive marbled pattern with fine color gradations while maintaining overall composition stability.
2Quantity of substance
If a limited number of basic colors are used, then production cost is reduced, but the optical design and visual appeal are compromised
Solution Approach 1:
The patent applies parameter changes by varying the mixing degree parameter across different regions rather than changing the number of basic colors. By controlling the extent of mixing (from complete to partial) among a limited set of basic colors, the invention generates a wide variety of visual effects including marbled patterns, color gradients, and transitional zones, thereby achieving high visual appeal without increasing material complexity.
3Manufacturing precision
If components are thoroughly mixed to create uniform intermediate products, then manufacturing precision is improved, but the marbled appearance and color gradations are lost
Solution Approach 1:
The patent applies partial action by intentionally not completely mixing all components throughout the entire material. Instead, mixing is applied partially or selectively to create zones with different degrees of homogeneity. This results in intermediate products that maintain sufficient consistency for manufacturing while preserving the partial mixing effects necessary for marbled patterns and color gradations in the final product.
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 process results in a stable, wear-resistant floor covering with a particularly attractive surface design, effectively hiding dirt and wear, and achieving fine color gradations with a limited number of basic colors.
Implementation Method 1
providing a first component and a second component, wherein the first and second components are miscible
Implementation Method 2
A short screw extruder is fed with two or three differently colored strips of vulcanizable elastomer material. The elastomeric material is conveyed through the extruder without color mixing, extruded through a perforated disc and cut into shaped pieces
Implementation Method 3
The molded pieces are then compressed into a web of material in a two-roll calender
Implementation Method 4
The mixing takes place in such a way that the components are not completely mixed. Accordingly, the different color gradations of the different first and second basic colors can be seen on the finished floor covering
Data Source
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AI summary
A method for manufacturing a patterned floor covering involves the following steps: providing a first component (1), a second component (2) and a third component (3); making an intermediate product (6) by mixing the first component (1) and the second component (2) in a mixing device (5); further processing the intermediate product (9) to obtain a web-type floor covering (13), the second intermediate product (9) being shaped. Also disclosed is a patterned floor covering obtainable by said method.