Foam Core Floor Plank Bonding Process
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Solution Overview
Problem
Existing composite laminated plastic tiles with solid layers require high pressures and temperatures for bonding, which can burst or compress the air cells in foam layers, increasing density and compromising the lightweight and dimensional integrity of foam-based structures.
Innovation Solution
A lightweight, multi-purpose composite tile with a foam base layer and a substrate layer bonded using a specific pressure and temperature range that maintains the foam's density and dimensional stability, incorporating a PVC foam base layer and a polyethylene or PVC substrate layer, with a design pattern and abrasion-resistant wear layer, and a method for forming grooves for corner flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high pressure and temperature are used for bonding composite laminated plastic tiles with solid layers, then bonding strength is improved, but the air cells in foam layers are burst or compressed, increasing density and compromising dimensional integrity
Solution Approach 1:
The patent applies parameter changes by establishing a specific bonding pressure range (10-50 psi) and temperature range (60-100°C) that are lower than conventional solid layer bonding conditions. This modified parameter set enables effective bonding of foam-containing composite tiles while preserving the foam's air cell structure, dimensional integrity, and lightweight properties
Solution Approach 2:
The patent uses composite materials by bonding a foam base layer with a substrate layer to create a multi-layer composite tile. The foam base layer provides lightweight properties and dimensional stability, while the substrate layer provides structural support and surface functionality, achieving both strength and foam integrity through proper material selection and bonding parameter control
2Weight of moving object
If foam base layer is used in composite tile, then lightweight property is improved, but bonding requires lower pressure and temperature, limiting manufacturing process options
Solution Approach 1:
The patent modifies the bonding parameters to lower pressure (10-50 psi) and temperature (60-100°C) ranges that are suitable for foam materials. This enables the use of foam base layers while maintaining manufacturing feasibility through adapted process conditions that preserve foam structure
Solution Approach 2:
The patent introduces an adhesive layer as an intermediary between the foam base layer and substrate layer. This adhesive mediator enables effective bonding at lower pressures and temperatures, expanding manufacturing process options for foam-containing composite tiles while maintaining strong bonds
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, dimensionally stable tile with good impact resistance, thermal insulation, and acoustical insulation, suitable for various applications without significant increase in density, facilitating easy handling and installation, and maintaining the foam's original thickness and density.
Implementation Method 1
The core layer provides the floor member with good impact resistance, thermal insulation, and acoustical insulation
Implementation Method 2
The core layer provides the floor member with good impact resistance, thermal insulation, and acoustical insulation
Data Source
AI summary
The floor member has a closed-cell foam core that constitutes approximately 50% of the overall thickness of the floor member. All constituents of the floor member, including a design layer, wear layer and resilient foam plastic underlayer, are highly water resistant and essentially water repellant. The closed-cell foam core is relatively lightweight and the floor member is also relatively lightweight compared to equally dimensioned floor planks formed exclusively of solid laminated plastic materials or wood-based laminated materials. The floor member has edge connecting means for convenient floating floor installation without the need to adhere the floor member to a floor base. The floor member is also easy to handle to permit a do-it-yourselfer to install a floor covering with the floor member.