Foamed-Backing Floor Panels for Sound Insulation and Stability
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Solution Overview
Problem
Existing floor coverings made from soft PVC telegraph subfloor irregularities over time, and rigid PVC panels have poor sound absorption properties, while thick acoustical layers in vinyl tiles increase thickness and compressibility.
Innovation Solution
Incorporating a foamed backing layer with a density of at least 120 kg/m³ and compressive strength of at least 210 kPa between the substrate and wear layer, which is thin enough to maintain stability and ease of installation while providing sound insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If soft PVC is used for the substrate, then the floor covering is flexible and easy to install, but irregularities of the subfloor are telegraphed over time through the floor covering
Solution Approach 1:
The substrate is divided into multiple layers: a soft PVC layer for flexibility and installation ease, and a rigid PVC reinforcement layer for stability and subfloor irregularity resistance. This segmentation allows each layer to perform its specific function without compromising the other.
Solution Approach 2:
The substrate uses a composite structure combining soft PVC and rigid PVC materials. The soft PVC provides flexibility and ease of installation, while the rigid PVC reinforcement layer provides dimensional stability and prevents telegraphing of subfloor irregularities.
2Reliability
If rigid PVC is used for the substrate, then subfloor irregularities are not telegraphed, but sound absorption properties are poor
Solution Approach 1:
The substrate is segmented into a rigid PVC layer for stability and a separate soft PVC layer for sound absorption. This allows the rigid layer to prevent telegraphing while the soft layer provides acoustic insulation.
Solution Approach 2:
The substrate combines rigid PVC and soft PVC in a composite structure where the rigid PVC provides dimensional stability and the soft PVC provides sound absorption, resolving the contradiction between stability and acoustic performance.
3Object-affected harmful factors
If a thick acoustical layer is added to vinyl tiles, then sound absorption is improved, but the total thickness increases and compressibility leads to local sinking
Solution Approach 1:
Sound absorption is achieved locally within the substrate structure itself through the soft PVC layer, rather than adding a separate thick acoustical layer. This provides acoustic insulation without increasing overall thickness or compromising stability.
Solution Approach 2:
The soft PVC layer within the substrate acts as an integrated acoustical component that provides sound absorption without the need for additional thick layers, maintaining floor stability while improving acoustic performance.
4Object-affected harmful factors
If the foamed backing layer density is increased, then sound insulation is improved, but the layer becomes more compressible and may cause local sinking
Solution Approach 1:
The foamed backing layer uses specific density parameters (0.3-0.6 g/cm³) and compression modulus parameters (0.03-0.15 N/mm²) to optimize the balance between sound insulation and compressive strength, preventing local sinking while maintaining acoustic performance.
Solution Approach 2:
The foamed backing layer uses a composite foam structure that provides sound insulation through its cellular structure while maintaining sufficient compressive strength to prevent excessive deformation and local sinking under load.
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 foamed backing layer effectively attenuates sound and prevents excessive vertical movement, offering a stable and easily installed floor covering with improved sound insulation.
Implementation Method 1
the foamed backing layer effectively attenuates sound
Implementation Method 2
The foamed backing layer has a density of at least 120 kg/m³ and compressive strength of at least 210 kPa
Data Source
Figure 1~3
Figure 4~7
AI summary
Floor panel comprising a substrate (20), a decorative layer (22) and a wear layer (24), the decorative layer (22) being positioned between the substrate (20) and the wear layer (24). At least one of the substrate, the decorative layer and the wear layer comprises a thermoplastic synthetic material. The floor panel (10) further includes a foamed backing layer (26) attached to a side of the panel opposite to the wear layer (24), the foamed backing layer having a density of at least 120 kg/m3 and preferably a compressive strength value as determined in accordance with ASTM D 3575-91 (25 %) of at least 210 kPa.