Glueless PVC Composite Flooring With Waterproof Layers

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Solution Overview

Problem

Existing flooring materials using compressed sawdust or glue are susceptible to water damage, premature failure, delamination, and complex manufacturing processes, limiting efficiency and durability.

Innovation Solution

A PVC-based flooring system with waterproof layers and UV-cured coatings, eliminating the need for glue and adhesives, and allowing continuous manufacturing with adjustable decorative patterns and textures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If compressed sawdust or dust is used as core material, then sound-deadening characteristic is improved, but water resistance deteriorates

Engineering Contradiction:

Improvesound-deadeningVSAvoidwater damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameter from compressed sawdust/dust to expanded polytetrafluoroethylene (ePTFE) foam, which fundamentally alters both the sound-absorbing and water-resistant properties. The ePTFE foam maintains sound-deadening capabilities while providing inherent water resistance, resolving the contradiction between acoustic performance and water resistance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite structure combining ePTFE foam core with PVC wear layer and backing layer. This composite material approach allows the ePTFE foam to provide both sound absorption and water resistance, while the PVC layers provide durability and wear resistance, solving the contradiction through material composition.

Inventive Principle:

Principle #40Composite materials

2Strength

If glue or adhesive is used to bind layers, then layer bonding is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvelayer bondingVSAvoidmanufacturing process

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the glue or adhesive step from the manufacturing process entirely. Instead of using adhesives to bond layers, the invention uses a mechanical interlocking system where the backing layer is mechanically attached to the core material, and the wear layer is bonded to the backing layer through a simplified process that removes the complex adhesive application and curing steps.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical bonding mechanism of adhesives with a mechanical bonding system. The backing layer is mechanically attached to the core material through a process that creates physical attachment without requiring adhesive chemicals, thereby reducing manufacturing complexity while maintaining layer bonding strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If polyurethane or two-part epoxy coating is used, then wear resistance is improved, but curing time increases

Engineering Contradiction:

Improvewear resistanceVSAvoidcuring time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent changes the coating chemistry from oxidative curing (polyurethane) or multi-component curing (two-part epoxy) to a single-component UV-curable coating system. This parameter change in the curing mechanism allows the coating to cure rapidly upon UV exposure, dramatically reducing curing time from hours to minutes while maintaining wear resistance through the UV-cured protective layer.

Inventive Principle:

Principle #35Parameter changes

4Manufacturing precision

If traditional printing methods are used for decorative patterns, then pattern application is improved, but design versatility deteriorates

Engineering Contradiction:

Improvepattern applicationVSAvoiddesign variation

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent implements a dynamic printing system that can be quickly reconfigured for different decorative patterns. The printing apparatus includes a movable printing element that can be adjusted and repositioned, allowing the same equipment to produce various designs, colors, and patterns without requiring complete system replacement, thereby enhancing design versatility while maintaining manufacturing precision.

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

Produces durable, high-performing flooring with efficient, continuous manufacturing and varied decorative options, avoiding water damage and delamination issues.

Implementation Method 1

a UV-cured top coating, optional

Methodology Applied

Scientific EffectUV curing: Photopolymerisation

Data Source

PatentEP3980238B1Method of producing a glueless dustless composite flooring material system

Publication Date: 2025.10.22 I4F LICENSING NV

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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 del ami nation 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.