Floor Panel Thin Thermoplastic Layer Wear Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing floor panels for floating floor coverings face issues such as moisture sensitivity, noise from hard surfaces, reduced transparency due to thick thermoplastic layers, and increased wear and deformability, leading to unwanted impressions and safety concerns.
Innovation Solution
A floor panel design featuring a substrate with a thin transparent thermoplastic top layer and a deep chamfer, where the thermoplastic layer is limited to 0.5 millimeters or less, and a harder substrate to minimize wear and impressions, combined with mechanical coupling means for secure locking and reduced moisture penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thick thermoplastic layer is used to provide wear resistance and form relief, then wear resistance is improved, but transparency is reduced and a plastic-like impression is created
Solution Approach 1:
The patent changes the thickness parameter of the transparent thermoplastic layer from conventional thick (1mm or more) to thin (0.1-0.5mm), which maintains wear resistance while improving transparency and eliminating the plastic-like appearance. This parameter optimization resolves the contradiction between wear resistance and transparency.
2Strength
If a thick thermoplastic layer is used to withstand wear at edges, then wear resistance is improved, but the edges become prone to being pushed upward causing safety issues
Solution Approach 1:
The patent reduces the thermoplastic layer thickness to 0.1-0.5mm, which prevents the layer from being pushed upward at edges while maintaining adequate wear resistance. This parameter change eliminates the safety hazard of upward-bulging edges.
Solution Approach 2:
The patent combines a thin thermoplastic layer with a rigid core layer to create a composite structure that provides edge stability and wear resistance without the plastic layer being pushed upward. The composite structure resolves the contradiction between wear resistance and edge stability.
3Strength
If a hard substrate and thick thermoplastic layer are used to create a hard surface, then wear resistance is improved, but ticking noises occur during use
Solution Approach 1:
The patent reduces the thermoplastic layer thickness to 0.1-0.5mm, which eliminates the ticking noise problem while maintaining surface hardness and wear resistance through the rigid core layer. The parameter change resolves the contradiction between surface hardness and noise generation.
4Strength
If a thick transparent layer is used to protect the print, then wear resistance is improved, but the view on the print is reduced due to lack of transparency
Solution Approach 1:
The patent optimizes the thermoplastic layer thickness to 0.1-0.5mm, which provides adequate print protection while maintaining high transparency for excellent print visibility. This parameter optimization resolves the contradiction between print protection and print visibility.
Data Source
Figure 1~4
Figure 5~7
Figure 8~12
AI summary
Floor panel comprising a substrate (6) and a top layer (7); wherein the substrate (6) substantially consists of a thermoplastic material; wherein the top layer (7) is at least composed of a print (9) and a transparent thermoplastic layer (10) situated above said print (9); wherein the floor panel (1) is provided with mechanical coupling means (18) which are substantially realized in said substrate (6); characterized in that the top layer (7) of the floor panel (1) comprises a back layer (8), which is situated between the print (9) and the substrate (6) and which comprises soft PVC; that the back layer (8) extends above the center line determined by the coupling means.