Thermoplastic Ground Coating with Smooth Surface and Mixed Particles
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Solution Overview
Problem
Current floor covering technologies face limitations in achieving a wide range of aesthetic aspects with a perfectly smooth surface, as homogeneous products are aesthetically limited due to restricted particle types and deformation, while heterogeneous products require expensive transparent plastisol and multiple costly steps, and neither can combine particles of different chemical natures or achieve a single-layer deposit.
Innovation Solution
A method and device that use a double belt press with lower pressure and temperature to pregel particles in a plastisol layer, allowing for a smooth surface and cohesive film without additional wear layers, while enabling the use of various particle types and sizes, and combining the advantages of both homogeneous and heterogeneous processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If homogeneous products are used to achieve a perfectly smooth surface, then surface smoothness is improved, but aesthetic variability deteriorates due to restricted particle types and deformation
Solution Approach 1:
The patent combines particles of different chemical natures (thermoplastic and mineral/metalllic particles) in a single coating layer, creating a composite material system that achieves both smooth surface and aesthetic variability. This resolves the contradiction by allowing diverse particle types to coexist without requiring separate homogeneous and heterogeneous processes.
2Adaptability or versatility
If heterogeneous products are used to achieve aesthetic variability, then aesthetic variability is improved, but production cost deteriorates due to expensive transparent plastisol and multiple steps
Solution Approach 1:
The patent merges the advantages of homogeneous and heterogeneous processes into a single integrated process. By using a distributor that can handle both thermoplastic and mineral particles simultaneously and applying them in one coating layer without requiring subsequent transparent plastisol layers, the invention reduces production steps and costs while maintaining aesthetic variability.
Solution Approach 2:
The invention extracts and eliminates the need for expensive transparent plastisol layers and multiple production steps that are characteristic of heterogeneous products. By achieving aesthetic variability directly through the particle mixture in a single layer, the patent removes the costly additional layers required in conventional heterogeneous processes.
3Adaptability or versatility
If conventional heterogeneous processes are used, then particle diversity is improved, but coating uniformity deteriorates due to inability to achieve single-layer deposit
Solution Approach 1:
The patent employs a dynamic distributor system (Villars type) that uses vibrations to control particle distribution and achieve uniform single-layer deposit. The vibrations allow particles to be evenly distributed and prevent clumping, enabling both particle diversity and coating uniformity to coexist in the same process.
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
This approach results in a floor covering with enhanced aesthetic variability, improved durability, and reduced production costs, maintaining a smooth surface and cohesion without additional wear layers, and allowing for the integration of diverse particle types and sizes.
Implementation Method 1
A method and device that use a double belt press with lower pressure and temperature to pregel particles in a plastisol layer
Implementation Method 2
placing said material particles in contact with said layer of liquid component under pressure and heat
Implementation Method 3
allowing for a smooth surface and cohesive film without additional wear layers
Data Source
AI summary
The invention relates to a method for making a ground coating made of a thermoplastic material, that comprises the steps of (a) depositing a layer of a liquid component on a substrate, the liquid component being selected from a plastisol, an organosol or an SBR rubber emulsion, (b) powdering solid particles on the liquid component layer, and (c) applying pressure and heat in order to form a ground coating having a smooth surface. The invention also relates to a device for obtaining such coatings.