Foamed Thermoplastic Floor Panel Substrate for Dimensional Stability
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Solution Overview
Problem
Existing floor panels made of soft PVC or extruded synthetic materials suffer from telegraphy effects, deformation, limited dimensional stability, and difficulty in installation due to flexibility and temperature variations, with coupling means providing limited strength and susceptibility to scratches and stains.
Innovation Solution
A floor panel design featuring a substrate with a centrally positioned foamed layer of thermoplastic material, reinforced by glass fiber layers, and non-foamed layers to enhance dimensional stability and resistance to deformation, coupled with precise locking mechanisms for improved installation and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a soft PVC substrate is used, then walking comfort is improved and ticking sound is reduced, but dimensional stability deteriorates and telegraphy effects occur
Solution Approach 1:
The substrate is constructed as a composite material system combining soft PVC layers with rigid reinforcement layers (glass fiber mat and/or CBS plasticizer-free PVC layers). This composite structure allows the soft PVC to provide walking comfort while the rigid reinforcement layers maintain dimensional stability and prevent telegraphy effects.
Solution Approach 2:
Different regions of the substrate have different properties: the soft PVC layers provide comfort and sound damping, while the rigid reinforcement layers (particularly at the back surface and intermediate layers) provide dimensional stability. This local differentiation of material properties resolves the contradiction between comfort and stability.
2Ease of operation
If a soft PVC substrate is used, then walking comfort is improved, but resistance to scratches and stains deteriorates
Solution Approach 1:
The substrate combines soft PVC layers with rigid, scratch-resistant reinforcement layers. The rigid layers (glass fiber mat and CBS plasticizer-free PVC) provide resistance to scratches and stains, while the soft PVC layers maintain walking comfort.
Solution Approach 2:
The surface layers and intermediate layers have different properties: soft PVC provides comfort, while rigid reinforcement layers provide scratch and stain resistance where needed.
3Strength
If an extruded synthetic material substrate is used, then resistance to deformation is improved, but dimensional stability deteriorates under temperature variations
Solution Approach 1:
The substrate uses a composite structure with PVC-based layers (which have good dimensional stability under temperature variations) combined with glass fiber reinforcement. This composite approach provides both deformation resistance and temperature stability, overcoming the limitations of extruded synthetic materials.
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 design provides enhanced dimensional stability, resistance to temperature variations, improved installation stability, and increased resistance to scratches and stains, while maintaining ergonomic advantages and sound damping properties.
Implementation Method 1
the substrate comprises at least a foamed layer of thermoplastic material
Implementation Method 2
an expansion of the elements may take place. The restricted stiffness of the floor panels will provide for that the floor covering will bulge locally
Implementation Method 3
a reinforcement layer having a more effective result for restricting possible dimensional expansions due to temperature variations
Data Source
AI summary
A floor panel with a substrate and a decoration provided thereon. The substrate includes at least a foamed layer of thermoplastic material and at least a reinforcement layer. Additionally, a method for manufacturing such floor panels with a substrate and a decoration, where the substrate includes at least a foamed layer of thermoplastic material and at least a reinforcement layer.