Crosslinked Polymer Cover Layer for Laminate Floor Sound Insulation
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Solution Overview
Problem
Existing laminate floor panels with elastic surfaces struggle to maintain a wood-like appearance and effectively insulate against structure-borne noise, particularly when embossing three-dimensional structures that mimic wood or natural materials, while also providing adequate impact sound insulation.
Innovation Solution
A cover layer with a physically or chemically crosslinked polymer outer layer and a softer functional layer, both made of thermoplastic elastomers, is used. The outer layer has a higher Shore hardness than the functional layer, offering scratch resistance and pleasant feel, while the functional layer absorbs mechanical shocks for effective sound insulation. This layer combination can be coextruded and applied as a prelaminate with a flexible carrier for enhanced durability and acoustic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an elastic surface layer is used to improve impact sound insulation, then acoustic properties are improved, but the visual impression of wood character and ability to emboss three-dimensional structures deteriorates
Solution Approach 1:
The cover layer is divided into two distinct layers: a hard outer layer (Shore hardness 80-95 A) that provides scratch resistance and accepts embossing, and a soft functional layer (Shore hardness 40-60 A) that provides impact sound insulation. This segmentation allows each layer to fulfill its specific function without compromising the other.
Solution Approach 2:
Different regions of the cover layer have different hardness properties tailored to their specific functions. The outer layer has high hardness for durability and embossing acceptance, while the inner functional layer has low hardness for acoustic insulation. This local differentiation resolves the contradiction between hard surface requirements and soft acoustic requirements.
2Ease of operation
If a soft elastic surface is used to improve warmth and acoustic properties, then comfort is improved, but scratch resistance and abrasion resistance deteriorate
Solution Approach 1:
The cover layer is segmented into a hard outer layer providing scratch and abrasion resistance, and a soft inner functional layer providing comfort and warmth. This segmentation allows the surface to be resistant to mechanical wear while remaining comfortable underfoot.
Solution Approach 2:
The outer layer is designed with high Shore hardness (80-95 A) for durability and resistance to scratches, while the inner layer has low Shore hardness (40-60 A) for comfort. This local quality differentiation simultaneously achieves both wear resistance and foot comfort.
3Ease of manufacture
If a single-layer elastic cover is used to simplify manufacturing, then device complexity is reduced, but the ability to provide both durability and acoustic insulation deteriorates
Solution Approach 1:
The cover layer is segmented into functional layers with distinct properties for durability and acoustics, achieved through coextrusion. This segmentation enables both durability and acoustic insulation to be provided simultaneously while maintaining manufacturing efficiency through a single coextrusion process.
Solution Approach 2:
The invention uses a composite structure with an outer layer of thermoplastic polymer (high hardness) and an inner layer of thermoplastic elastomer (low hardness). This composite material approach combines the advantages of both materials - durability from the thermoplastic and acoustic insulation from the elastomer - in a single integrated component.
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 durable structure-borne noise insulation, maintains a wood-like appearance, and enhances the acoustic properties of laminate floor panels, ensuring effective impact sound reduction and a pleasant walking experience while allowing for the embossing of fine wood-like structures.
Implementation Method 1
The functional layer absorbs mechanical shocks within the composite and has an effective footfall sound insulation effect
Implementation Method 2
an outer layer (3) made from a physically or chemically crosslinked polymer and at least one functional layer (4) also made from a physically or chemically crosslinked polymer
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The transparent covering layer (2) comprises an outer layer (3) made from a physical or chemical crosslinked polymer, and a functional layer (4) made from a physical or chemical cross linked polymer. The functional layer is formed underside of the outer layer. The outer layer has a Shore hardness of shore 60 D. The functional layer has a Shore hardness of shore 70 A. The covering layer has a total thickness of 50-2000 mu m. The outer layer has a layer thickness of 30-100 mu m. The functional layer has a layer thickness of 100-500 mu m. The covering layer further comprises a layer arrangement. The transparent covering layer (2) comprises an outer layer (3) made from a physical or chemical crosslinked polymer, and a functional layer (4) made from a physical or chemical crosslinked polymer. The functional layer is formed underside of the outer layer. The outer layer has a Shore hardness of shore 60 D. The functional layer has a Shore hardness of shore 70 A. The covering layer has a total thickness of 50-2000 mu m. The outer layer has a layer thickness of 30-100 mu m, and the functional layer has a layer thickness of 100-500 mu m. The covering layer further comprises a layer arrangement that includes alternatively arranged co-extruded layers such as hard layers and soft layers. The co-extruded layers consist of a physical or chemically crosslinked thermoplastic polymer, and have a Shore hardness corresponding to the outer layer. The soft layers have a Shore hardness corresponding to the functional layer. The covering layer is printed on its underside. The outer layer comprises a three-dimensional surface structure. A paint layer (8) coating is applied on a free side of the outer layer. An independent claim is included for a pre-laminate.