Glueless Composite Flooring With Waterproof PVC Layers
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Solution Overview
Problem
Existing flooring materials using compressed dust and adhesives are prone to water damage, premature failure, delamination, and complex manufacturing processes, limiting efficiency and decorative pattern flexibility.
Innovation Solution
A PVC-based flooring system with waterproof layers, UV-cured coating, and glueless, adhesive-free construction, allowing continuous manufacturing and customizable decorative patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compressed dust is used as core material, then sound-deadening characteristic is improved, but water resistance deteriorates
Solution Approach 1:
The patent changes the material parameter from compressed dust to expanded polystyrene foam, transforming the core material's properties to achieve both sound absorption and water resistance. The foam structure provides acoustic insulation while being inherently waterproof, resolving the contradiction between sound-deadening and water resistance.
Solution Approach 2:
The patent uses a composite structure combining expanded polystyrene foam core with PVC protective layers. This composite material system integrates the sound-absorbing properties of the foam with the water and wear resistance of PVC, achieving both sound-deadening and water resistance simultaneously.
2Strength
If glue or adhesive is used to bind layers, then layer bonding strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent removes the adhesive layer entirely from the flooring construction. Instead of using glue to bond the PVC protective layer to the expanded polystyrene foam core, the design uses direct thermal bonding or mechanical interlocking, eliminating the complex adhesive application and curing processes while maintaining layer bonding strength.
Solution Approach 2:
The patent replaces the chemical bonding mechanism of adhesives with a mechanical or thermal bonding system. The PVC layer is bonded to the foam core through heat welding or interlocking structures, substituting the complex chemical curing process with a simpler mechanical or thermal process that enables continuous manufacturing.
3Strength
If traditional finishing coatings are applied, then wear resistance is improved, but curing time increases
Solution Approach 1:
The patent changes the coating chemistry from traditional oxidative curing systems to UV-curable coatings. The finishing coating contains UV-active monomers that polymerize rapidly upon exposure to ultraviolet light, reducing curing time from hours to minutes while maintaining excellent wear resistance and chemical resistance properties.
4Reliability
If adhesive application process is included, then layer bonding is improved, but productivity decreases
Solution Approach 1:
The patent extracts and eliminates the adhesive application step from the manufacturing process. By designing a glueless construction method where the PVC protective layer is directly bonded to the expanded polystyrene foam core through thermal or mechanical means, the production line can operate continuously without stopping for adhesive application or curing, significantly improving productivity.
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, flexible production capable of rapid design changes, avoiding water damage and delamination issues.
Implementation Method 1
a UV-cured top coating
Data Source
AI summary
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 dust 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.