Linoleum floor covering
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Solution Overview
Problem
Traditional linoleum floor coverings face issues with dimensional stability and curling due to differential stresses, particularly with pre-cut tiles, and previous solutions like open mesh woven fabrics result in telegraphing and reduced flexibility due to thick carriers.
Innovation Solution
A linoleum floor covering design featuring two linoleum layers bonded through openings in a thin, low-weight reinforcement layer made of knitted material with a high openness factor, eliminating the need for additional adhesives and reducing material thickness and weight, thereby enhancing dimensional stability and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a thick carrier layer is used to prevent telegraphing, then the carrier structure is hidden from the surface, but the flexibility of the material is reduced and material consumption increases
Solution Approach 1:
The patent applies a porous reinforcement layer with high openness factor (at least 50%) that allows the linoleum layers to bond through the openings while maintaining dimensional stability. This porous structure prevents telegraphing by providing sufficient thickness (0.05-0.5 mm) to hide the carrier structure, while the high porosity keeps the layer thin and lightweight, preserving flexibility.
Solution Approach 2:
The patent uses a composite construction with a reinforcement layer made of specific materials (polyester, polyamide, polyacrylic, or aramid fibers) combined with linoleum layers. This composite approach creates a balanced structure where the reinforcement layer provides dimensional stability and telegraphing prevention, while the overall thin design maintains flexibility.
2Stability of the object's composition
If a conventional open mesh woven fabric carrier is used to provide dimensional stability, then the material gains acceptable dimensional stability, but differential stresses still cause unacceptable curling and complex control measures are needed
Solution Approach 1:
The patent changes key parameters of the reinforcement layer: using a thin thickness (0.05-0.5 mm), high openness factor (≥50%), and specific material composition. These parameter changes create a balanced construction that provides dimensional stability through the linear expansion coefficient match (0.5-5.0 × 10^-6/K) while eliminating the need for complex manufacturing controls.
Solution Approach 2:
The patent creates a more homogeneous and balanced construction where the reinforcement layer is integrated between two linoleum layers with adhesive layers. This homogeneous structure distributes stresses evenly and eliminates the heterogeneity of conventional carriers, preventing curling without complex controls.
3Object-affected harmful factors
If the linoleum wear layer is made thicker to counteract carrier variation and prevent telegraphing, then telegraphing is avoided, but material consumption and production costs increase
Solution Approach 1:
The patent uses a porous reinforcement layer with high openness factor that provides sufficient thickness (0.05-0.5 mm) to prevent telegraphing while minimizing material consumption. The porosity allows the layer to be thin yet effective at hiding the carrier structure, eliminating the need for thick linoleum layers.
Solution Approach 2:
The reinforcement layer acts as an intermediary between the subfloor and the wear layer, providing the necessary thickness and stability to prevent telegraphing. This intermediary structure allows the wear layer to be thinner since the reinforcement layer, not the wear layer, is responsible for counteracting carrier variation.
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 linoleum floor covering with improved dimensional stability, reduced telegraphing, and increased flexibility, allowing for thinner layers and reduced material consumption while maintaining strong bonding between layers without additional adhesives, making it suitable for tiles and panels.
Implementation Method 1
The first and second linoleum layers at opposite sides of the reinforcement layer are bonded to each other through the through openings
Implementation Method 2
a first layer (2) of cured linoleum composition and a second layer (3) of cured linoleum composition
Data Source
Figure 1~2
Figure 3
AI summary
The present invention provides a linoleum floor covering comprising: a first layer of cured linoleum composition; a second layer of cured linoleum composition, and a reinforcement layer having multiple through openings arranged between the first layer and the second layer, wherein a combined surface area of the through openings is at least 50% of the total surface are of the reinforcement layer, wherein the first layer and second layer are adhered to each other through the through openings, and wherein the reinforcement layer is made of knitted material.