Foamed PVC Flooring Backing Pad for Anti-Slip and Noise Reduction
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Solution Overview
Problem
Conventional anti-slip and noise-reducing backing layers for flooring materials are insufficient in providing anti-slip functionality, costly, and inefficient in production, requiring high labor costs for application.
Innovation Solution
A pasty or tacky PVC material is directly coated on the back of flooring materials and foamed during production to create a self-adhering, anti-slip, noise-reducing pad with a resilient outer surface and soft inner structure, applied in a pattern covering between 40% and 85% of the area, potentially including a mesh for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional backing materials (IXPE foam, EVA foam, rubber, cork, plastic film) are adhered to the back of flooring materials with adhesive, then noise reduction and cushioning are provided, but anti-slip functionality is insufficient and production labor costs are high
Solution Approach 1:
The patent combines the backing layer and adhesive layer into a single integrated PVC-based composite material. The adhesive is mixed with PVC powder and applied simultaneously with the backing layer, eliminating the need for separate adhesive application steps and reducing labor costs while maintaining strong bonding and anti-slip properties
Solution Approach 2:
The PVC-based composite material serves multiple functions simultaneously: it provides noise reduction, cushioning, anti-slip functionality, and adhesive bonding in a single layer. This multi-functional material replaces the need for separate backing materials and adhesives, streamlining the production process
2Object-affected harmful factors
If a backing layer is adhered to the back of flooring materials with adhesive, then noise reduction is provided, but the production process involves high labor costs and inefficiencies
Solution Approach 1:
The adhesive is pre-mixed with PVC powder and applied together with the backing layer in a single coating operation. This preliminary combination of materials eliminates subsequent adhesive application steps, improving production efficiency while maintaining noise reduction performance
Solution Approach 2:
The patent enables continuous production by applying the PVC-based composite material in a single continuous coating process. The material is applied, dried, and cured in sequence without interruption, eliminating the need for separate adhesive application and bonding steps, thereby improving production efficiency
3Strength
If conventional backing materials are used with adhesive, then cushioning is provided, but the process requires separate adhesive application increasing complexity
Solution Approach 1:
The backing layer and adhesive are merged into a single PVC-based composite material applied in one step. This simplifies the application process from multiple steps (applying backing, then applying adhesive) to a single coating operation, reducing process complexity while maintaining cushioning strength
Solution Approach 2:
The adhesive and PVC powder are thoroughly mixed to create a homogeneous composite material. This uniform mixture ensures consistent application and performance throughout the backing layer, eliminating variability associated with separate material applications
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 reduces labor costs, provides effective anti-slip and noise reduction, improves sound insulation and dampening, and allows for continuous production without separate adhesives, while offering aesthetic customization options.
Implementation Method 1
foaming the PVC material by heating the PVC material so as to form a foamed PVC anti-slip, noise reducing pad
Implementation Method 2
The PVC material may have properties allowing it to expand into a foam-like structure when heated
Implementation Method 3
After being heated and foamed, and then subject to rapid cooling or quenching, the PVC material may have properties allowing it to retain a fixed and formed shape with a resilient outer surface layer
Data Source
AI summary
Flooring material has an anti-slip, noise reducing pad directly self-adhered to a bottom surface. The pad is formed by applying a foamable PVC material is directly on the bottom surface of the flooring and heating the PVC material to foam the PVC material. The PVC material may then be cooled to form the pad with a definite formed shape having a resilient outer surface layer and a spongy foamy inner structure.