Interlocking LVT Tile Manufacturing Process
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Solution Overview
Problem
Current processes for producing interlocking LVT floor coverings are inefficient, costly, and inconvenient, particularly in comparison to the need for a quicker and more cost-effective method for manufacturing modular flooring systems.
Innovation Solution
A process involving injection moulding to form a base substrate with locating guides, coating the LVT surface layer with adhesive, aligning and press rolling to create an oversized blank, and punching out an interlock shape using a punch and die tool, which results in interlocking multi-layered LVT tiles with dovetail connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If co-extrusion and hot press process are used to produce interlocking LVT floor coverings, then the flooring can be manufactured with traditional methods, but the production efficiency is low and costs are high
Solution Approach 1:
The manufacturing process is segmented into distinct stages: injection molding the base substrate with locating guides, separately preparing the LVT surface layer with adhesive coating, and then combining them through press rolling. This segmentation allows each component to be optimized independently and assembled efficiently, resolving the contradiction between productivity and ease of manufacture.
Solution Approach 2:
The base substrate is pre-formed with locating guides during injection molding, and the LVT surface layer is pre-coated with adhesive before assembly. These preliminary actions eliminate the need for complex alignment and bonding operations during final assembly, significantly improving production efficiency while maintaining manufacturing simplicity.
2Ease of manufacture
If traditional co-extrusion and hot press process are used, then existing manufacturing capabilities can be utilized, but the process is costly and inconvenient
Solution Approach 1:
The traditional hot press process is replaced with a combination of injection molding and press rolling operations. Injection molding provides precise geometric control and integrates locating guides directly into the base substrate, while press rolling offers simpler, faster adhesive bonding. This substitution improves both manufacturing convenience and production speed.
3Productivity
If injection moulding is used to form the base substrate with locating guides, then production efficiency is enhanced and costs are reduced, but the process requires new manufacturing methods
Solution Approach 1:
The locating guides are merged directly into the base substrate during injection molding, eliminating the need for separate guide components and assembly steps. This integration simplifies the overall process while maintaining high production efficiency, as the complex locating feature is created in a single molding operation rather than requiring additional manufacturing steps.
4Manufacturing precision
If the LVT surface layer is aligned using locating guides and press rolled to form an oversized blank, then manufacturing precision is improved, but the process requires additional alignment steps
Solution Approach 1:
The locating guides on the base substrate perform the alignment function automatically when the LVT surface layer is placed upon it. The physical geometry of the guides and corresponding features on the surface layer create self-aligning conditions, eliminating the need for complex external alignment equipment or procedures while achieving high manufacturing precision.
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 process enhances production efficiency, reduces costs, and facilitates the creation of high-quality interlocking LVT tiles with improved bend strength and impact resistance, offering a more convenient method for manufacturing modular flooring systems.
Implementation Method 1
coating the back of an LVT surface layer with adhesive; aligning the LVT surface layer to a top surface of the base substrate
Implementation Method 2
press rolling the base substrate and LVT surface layer together to form an oversized blank
Data Source
AI summary
The invention provides a process of producing an interconnecting multi-layered LVT tile for a modular flooring system, the process comprising the steps of: a) forming a base substrate of plastics material with at least one locating guide by injection moulding; b) coating the back of an LVT surface layer with adhesive; c) aligning the LVT surface layer to a top surface of the base substrate such that the LVT surface layer abuts the or each locating guide of the base substrate; d) press rolling the base substrate and LVT surface layer together to form an oversized blank; and e) punching out an interlock shape from the oversized blank using a punch and die tool.