Glass Fiber Thermoplastic Floor Panel for Dimensional Stability
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Solution Overview
Problem
Existing floor panels made of thermoplastic materials, particularly vinyl-based panels, suffer from significant shrinkage and expansion due to temperature changes, leading to gaps and instability, and existing methods for enhancing dimensional stability, such as glass fiber reinforcement, either compromise flexibility or are time-consuming and limited in design variation.
Innovation Solution
The use of thermoplastic panels with strewn and pressed granulate layers enclosing a glass fiber layer, preferably a glass fiber fleece, and individual fibers with specific properties to enhance stability, combined with a printed decor and transparent wear layer, provides improved dimensional stability and locking mechanisms for secure coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If glass fiber reinforcement is applied to increase dimensional stability, then shrinkage and expansion are reduced, but the flexibility and adaptability to uneven surfaces deteriorate
Solution Approach 1:
The patent applies glass fiber reinforcement locally only in the core layer of the panel, while the wear layer and backing layer remain flexible without fiber reinforcement. This localized application provides dimensional stability where needed (in the core) while preserving flexibility in the surface and backing layers for adaptability to uneven surfaces.
Solution Approach 2:
The patent creates a composite panel structure with multiple layers having different properties: a flexible thermoplastic wear layer, a glass fiber-reinforced core layer for stability, and a flexible backing layer. This composite construction allows each layer to contribute its specific properties, achieving both dimensional stability and flexibility simultaneously.
2Manufacturing precision
If traditional manufacturing methods are used, then production is simpler, but manufacturing precision and consistency in dimensional stability are insufficient
Solution Approach 1:
The patent divides the panel into distinct functional layers (wear layer, core layer with glass fiber, backing layer) that can be manufactured separately and then laminated together. This segmentation allows each layer to be optimized independently for its specific function while maintaining overall manufacturing efficiency through modular production.
Solution Approach 2:
The glass fiber mat is pre-placed in the core layer position before the thermoplastic material is extruded and laminated onto it. This preliminary positioning ensures consistent placement and distribution of the reinforcing fibers, achieving uniform dimensional stability across all panels without requiring complex post-processing.
3Reliability
If coupling means are provided for locking panels, then mutual locking is achieved, but the complexity of the panel structure increases
Solution Approach 1:
The patent integrates the coupling means directly into the panel edges as protrusions and grooves that are formed as part of the panel manufacturing process itself, rather than as separate attached components. This merging of the coupling function into the basic panel structure achieves reliable locking while minimizing additional complexity.
Solution Approach 2:
The coupling means serve multiple functions: they provide mechanical locking between panels, ensure proper alignment during installation, and contribute to the overall structural integrity of the flooring system. This multi-functionality reduces the need for separate components for each function.
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 significantly reduces shrinkage and expansion issues, ensuring a stable and securely locked floor covering with improved wear resistance and adaptability to uneven surfaces, maintaining quality and stability over time.
Implementation Method 1
The panels of the state of the art show the disadvantage that they are strongly subjected to shrinkage and expansion, or even bending, under the influence of temperature
Data Source
AI summary
Panel for forming a floor covering, where this panel has at least two layers of thermoplastic material, where the two layers substantially have a strewn and pressed granulate, where the respective layers enclose a glass fiber layer.