Floor Covering Mineral Particle Density Control
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Solution Overview
Problem
Existing floor coverings with mineral decorative particles face issues of sinking particles due to high density and round shape, leading to inadequate surface coverage and mechanical effectiveness, requiring excessive application quantities to achieve a sufficient surface effect.
Innovation Solution
Incorporating mineral decorative particles with a density less than 3 kg/dm³ and low sphericity, specifically between 0.35 mm and 1.4 mm in size, which are embedded into an elastomeric base material during vulcanization, ensuring they remain visible and integrated on the surface, enhancing both optical and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high-density corundum particles are used to increase surface coverage, then the surface effect is improved, but the particles sink into the matrix reducing surface coverage
Solution Approach 1:
The patent changes the density parameter of the decorative particles from high-density corundum (>3.9 g/cm³) to low-density mineral particles (2.6-2.8 g/cm³), which fundamentally alters the sinking behavior during vulcanization and improves surface retention without requiring additional process steps
Solution Approach 2:
Instead of using hard, dense particles that sink into the matrix, the patent inverts the approach by using softer, less dense mineral particles that naturally float or remain at the surface during processing, achieving the opposite effect of what conventional wisdom would suggest
2Illumination intensity
If corundum particles are scattered onto the surface to achieve decorative effect, then the optical surface effect is improved, but the particles sink due to high density and round shape
Solution Approach 1:
The patent modifies multiple particle parameters simultaneously: density (reducing from 3.9 to 2.6-2.8 g/cm³), shape (using irregular angular fragments rather than spherical particles), and size distribution (0.3-2.0 mm), which collectively prevent sinking and maintain surface position during vulcanization
Solution Approach 2:
The patent uses composite mineral particles consisting of natural stone fragments with specific physical properties, combining low density, irregular shape, and appropriate size to achieve both optical effectiveness and surface retention in the elastomeric matrix
3Quantity of substance
If a large application quantity of particles is used to achieve sufficient surface effect, then the surface coverage is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
By changing the density parameter of the particles to be lower than the elastomeric matrix, the patent achieves self-retention of particles at the surface during vulcanization, eliminating the need for complex post-treatment equipment such as calenders or additional bonding mechanisms
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 approach allows for a significant surface coverage of decorative particles, improving the floor's optical and mechanical properties, including slip resistance, while being easier to manufacture and maintain, with particles like granite and mica being soft enough for conventional cutting.
Implementation Method 1
the sinking behavior of jewelry particles depends in particular on the density of the particles. It is true that jewelry particles with a density of more than 3 kg/dm 3
Implementation Method 2
the sphericity, also known as roundness, of a jewelry particle is determined by the ratio between the surface area of a jewelry particle and its circumference
Implementation Method 3
that provided with the jewelry particles Base material is fed to a vulcanization device for vulcanization
Implementation Method 4
mineral decorative particles improve the slip resistance of an elastomeric floor covering
Data Source
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AI summary
The invention relates to a floor covering (1) comprising a web- or plate-shaped base material (2) made from an elastomer material, wherein the base material (2) is provided with mineral decorative particles (3), and wherein the density of the mineral decorative particles (3) is not greater than 3 kg/dm3.