Glueless Composite Flooring via UV Curing and Mechanical Bonding

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Solution Overview

Problem

Existing flooring materials face issues such as water damage, premature delamination, and manufacturing bottlenecks due to the use of compressed cellulose materials and adhesives, which also complicate the application of decorative patterns and textures.

Innovation Solution

A PVC-based glueless dustless composite flooring material system is developed, featuring waterproof layers fused together without adhesives, with optional underlayment and UV-cured top coating, allowing for continuous-run manufacturing and quick design changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If compressed sawdust or dust is used as core material, then sound-deadening characteristics are provided, but the flooring becomes susceptible to water damage and premature failure

Engineering Contradiction:

Improvesound-deadening characteristicsVSAvoidresistance to water damage

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The patent removes compressed cellulose materials (sawdust, dust) from the flooring composition entirely, extracting the problematic element that causes water damage while seeking alternative materials that can provide sound-deadening characteristics without the water susceptibility of compressed organic materials

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention uses composite materials consisting of rigid foam core layers combined with decorative wear layers, creating a multi-material construction that provides both structural integrity and sound-deadening properties without relying on water-vulnerable compressed cellulose

Inventive Principle:

Principle #40Composite materials

2Strength

If glue or adhesive is used to bind layers, then layers are bound together, but the process becomes complex and prone to delamination in damp environments

Engineering Contradiction:

Improvelayer bondingVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent eliminates adhesives and glues from the flooring construction, removing the bonding agent that creates manufacturing complexity and delamination risks, and instead uses mechanical interlocking through tongue-and-groove profiles

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention replaces the chemical bonding system (adhesives) with a mechanical bonding system (tongue-and-groove interlocking profiles), substituting one type of joining mechanism for another that avoids the complexities and failures associated with adhesive application and curing

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If polyurethane or two-part epoxy coating is applied, then adhesion is improved, but curing time increases and manufacturing efficiency decreases

Engineering Contradiction:

Improvecoating adhesionVSAvoidmanufacturing speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent changes the curing parameters of the coating system by using UV-curable coatings that cure in minutes under ultraviolet light, dramatically reducing the curing time compared to conventional polyurethane (8-10 hours) or two-part epoxy (30+ minutes) coatings, thereby maintaining adhesion while enabling continuous manufacturing

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If conventional printing methods are used for decorative patterns, then patterns are applied, but registration problems occur and design changes are difficult

Engineering Contradiction:

Improvepattern applicationVSAvoiddesign flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent implements a dynamic printing system using digital printing technology that can be quickly reconfigured for different decorative patterns, colors, and designs, allowing the manufacturing process to adapt flexibly to changing design requirements without the registration and retooling problems of conventional fixed-pattern printing methods

Inventive Principle:

Principle #15Dynamics

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 provides a durable, long-lasting, and high-performing flooring material that is resistant to water damage and delamination, while enabling efficient and cost-effective manufacturing with varied decorative options.

Implementation Method 1

with UV-cured top coating

Methodology Applied

Scientific EffectUV curing: Photopolymerisation

Data Source

PatentUS20250135700A1Method of Producing a Glueless Dustless Composite Flooring Material System

Publication Date: 2025.05.01 I4F LICENSING NV

AI summary

A method of producing a glueless dustless composite flooring material system providing PVC-based flooring having waterproof layers providing different qualities of hardness, wear-resistance, sound deadening, and decorative patterns, avoiding the use of moisture-susceptible compressed cellulose-based filler, with layers fused together, avoiding the manufacturing complexity and delamination risks of using glue or adhesive, with a quickly-cured, UV-cured top coating providing long-lasting high performance and shortening and simplifying the manufacturing, which can be done in a sheet-form, essentially continuous-run manner, with an ability to quickly and simply change the optional design printing and texturing produced, and having an optional underlayment layer.