Foam Composite Tile Bonding Under Low Pressure
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Solution Overview
Problem
Existing composite laminated plastic tiles require high pressures and temperatures for bonding, which can burst or compress foam layers, increasing density and compromising the lightweight and dimensional integrity of the tiles.
Innovation Solution
A lightweight, multi-purpose composite flexible plastic tile with a foam base layer and a substrate layer bonded using a specific adhesive under controlled pressure and temperature conditions, maintaining the foam layer's density and dimensional stability, and featuring a design pattern protected by an abrasion-resistant wear layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high pressure and temperature are used for bonding composite laminated plastic tiles, then bonding strength is improved, but foam layer density increases and dimensional integrity is compromised
Solution Approach 1:
The patent changes the bonding parameters by using low pressure (0.1 to 0.5 MPa) and low temperature (room temperature or slightly elevated) bonding processes, replacing the conventional high pressure and temperature method. This parameter change allows the foam layer to maintain its original density and dimensional integrity while achieving sufficient bonding strength through the use of flexible adhesive compositions and extended bonding time.
Solution Approach 2:
The patent employs a composite material system consisting of multiple layers including foam layers, substrate layers, and flexible adhesive compositions with specific polymer blends (such as polyvinyl chloride, polyethylene, and polypropylene). This composite structure allows each layer to contribute its specific properties: the foam provides lightweight insulation, the substrate provides structural support, and the flexible adhesive provides bonding without transmitting excessive stress that would compress the foam.
2Weight of moving object
If foam layers are used to reduce tile weight, then weight is reduced, but bonding difficulty increases due to foam compressibility
Solution Approach 1:
The patent introduces a flexible adhesive composition as an intermediary material between the foam layer and the substrate. This adhesive acts as a mediator that accommodates the compressibility of the foam while still achieving reliable bonding. The adhesive's flexibility allows it to conform to the foam's deformation without transmitting excessive stress, thereby facilitating the bonding process despite the foam's compressible nature.
Solution Approach 2:
The patent changes the bonding parameters by using low pressure (0.1 to 0.5 MPa) and extended bonding time, replacing the conventional high pressure method. This parameter change allows the foam layer to maintain its original density and dimensional integrity while achieving sufficient bonding strength through the use of flexible adhesive compositions and extended bonding time.
3Strength
If rigid bonding is used to ensure structural strength, then strength is improved, but flexibility and ease of installation are reduced
Solution Approach 1:
The patent changes the mechanical properties of the bonding system by using flexible adhesive compositions with specific polymer blends and plasticizers that provide elasticity and flexibility. The adhesive maintains sufficient bonding strength while allowing the tile to be bent and folded for corner installations, thereby achieving both structural strength and operational flexibility.
Solution Approach 2:
The patent employs a composite material system where the flexible adhesive composition (containing polymers like polyvinyl chloride, polyethylene, and polypropylene along with plasticizers) creates a bonding interface that combines the strengths of rigid bonding with the flexibility needed for installation. This composite bonding system allows the tile to maintain structural integrity while being easy to install in various configurations.
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 solution results in a lightweight, impact-resistant, thermally and acoustically insulated tile that is easy to install and maintain, with a design that can be easily bent or folded for corner installations, while preserving the foam layer's original density and stability.
Implementation Method 1
A lightweight, multi-purpose composite flexible plastic tile with a foam base layer and a substrate layer bonded using a specific adhesive under controlled pressure and temperature conditions
Implementation Method 2
a lightweight, impact-resistant, thermally and acoustically insulated tile
Implementation Method 3
a lightweight, impact-resistant, thermally and acoustically insulated tile
Implementation Method 4
featuring a design pattern protected by an abrasion-resistant wear layer
Data Source
Figure 1~2
Figure 2A~3
Figure 4~6
AI summary
A multi-purpose tile is installable on ceilings walls and floors. The tile includes a base layer of foam plastic material bonded to an upper substrate layer of non-foam plastic or metal material. The bonding process includes pressurization of the foam layer to the non-foam constituents of the tile. The pressure is at a selected level that basically does not change the density of the foam base layer before and after pressurization. The thickness ratio of the foam based layer relati ve to other constituent layers of the tile can be approximately 15 to 20 times thicker than the other constituent layers thus ensuring that the tile is a lightweight, low density structure that is easy to handle and install.