Floor Tile Manufacturing Process Eliminating Air Bubbles
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Solution Overview
Problem
Existing manufacturing processes for floor tiles using double-belt presses often result in large air bubbles within the tiles, affecting their quality and potentially damaging the conveyor belt.
Innovation Solution
A process involving a core layer with multiple layers of thermoplastic material and glass fiber sheets, where the sheets are impregnated with thermoplastic material during hot pressing, eliminating air bubbles and enhancing tile quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcement layers are added to the core layer using conventional double belt press methods, then the structural strength of the floor tile is improved, but large air bubbles form within the tiles affecting quality and potentially damaging the conveyor belt
Solution Approach 1:
The core layer is segmented into multiple sub-layers (first core sub-layer, second core sub-layer, third core sub-layer) with reinforcement layers positioned at specific interfaces. This segmentation allows for controlled placement of reinforcement materials while facilitating complete evacuation of air bubbles from each interface during the molding process, preventing void formation that would compromise tile quality.
Solution Approach 2:
The reinforcement layers are pre-positioned at the interfaces between core sub-layers before the final molding and compression steps. By preparing the layered structure in advance with proper alignment and ensuring all air can escape through the open end of the mold, the process eliminates air bubble entrapment that would otherwise occur with conventional single-step reinforcement methods.
2Strength
If reinforcement layers are added to the core layer, then the structural strength of the floor tile is improved, but air bubbles appear on the surface causing holes and potential degradation of the conveyor belt
Solution Approach 1:
The core layer is divided into multiple sub-layers with reinforcement layers at specific interfaces, creating a segmented structure that allows air bubbles to escape during molding. This segmentation prevents air entrapment that would cause surface holes while maintaining the strength benefits of reinforcement.
Solution Approach 2:
The mold design incorporates an open end specifically to allow air bubbles to escape during the molding process. By providing a designated escape path for air, the process converts the potentially harmful air bubbles into a controlled evacuation process, eliminating surface defects while maintaining reinforcement benefits.
3Ease of manufacture
If conventional pressing methods are used to create the core layer with reinforcement, then the manufacturing process is simple, but the quality of the tiles is degraded due to air bubbles
Solution Approach 1:
The core layer is segmented into multiple sub-layers with reinforcement layers at specific interfaces. This segmentation maintains relative manufacturing simplicity while eliminating air bubble formation, thus improving tile quality without significantly complicating the manufacturing process.
Solution Approach 2:
The reinforcement layers are pre-positioned at interfaces between core sub-layers before final molding. This preliminary arrangement of layers, combined with the open-end mold design that allows air escape, achieves high-quality bubble-free tiles while maintaining a straightforward manufacturing sequence.
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 ensures bubble-free tiles with improved quality and extends the lifespan of the conveyor belt by preventing damage from air bubbles.
Implementation Method 1
The press allows pressing and heating the granules between the first belt and a second belt of the press in order to transform the granules into a core layer of the slab
Implementation Method 2
The press allows pressing and heating the granules between the first belt and a second belt of the press in order to transform the granules into a core layer of the slab
Data Source
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AI summary
A process for manufacturing floor tiles comprising the following steps: - scattering granules (62) of a thermoplastic material on a conveying member (52) in order to obtain a first layer of granules (64), - superimposing several sheets (5B, 5C) in order to obtain a plurality of adjacent sheets on the first layer of granules (64), each of the sheets containing at least 50 wt% of glass fibers, - scattering granules (70) of a thermoplastic material on the uppermost sheet (5B) in order to obtain a second layer of granules (72), - pressing and heating the first layer of granules, the plurality of adjacent sheets and the second layer of granules, - melting or at least softening the first layer of granules and the second layer of granules, the plurality of sheets being at least partly impregnated by the thermoplastic material of the first layer of granules and of the second layer of granules in order to obtain a core layer after cooling, and - using the core layer to produce at least a slab, and using the slab to obtain the floor tiles.