Marble Tile-Imitating SPC Floorboard With Grout-Look Grooves
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Solution Overview
Problem
Traditional marble imitation tiles are heavy, costly, and difficult to install, with gaps between tiles that require grouting, which can lead to aging and failure due to thermal expansion differences, while SPC floorboards lack aesthetic variety and high-end decoration effects.
Innovation Solution
A marble tile-imitating SPC floorboard with a multi-layer structure comprising a wear-resistant layer, decoration layer, first and third SPC substrate layers, and a foamed second SPC substrate layer, featuring a groove to mimic tile grout, made through co-extrusion and planing to achieve a realistic marble pattern and simplified installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional marble imitation tiles are used, then aesthetic appearance and durability are improved, but weight and installation complexity increase
Solution Approach 1:
The patent uses a decoration layer with marble patterns that visually copies the appearance of traditional marble tiles, while the underlying structure uses lightweight SPC (stone plastic composite) material instead of actual stone, achieving the aesthetic effect without the weight
Solution Approach 2:
The invention employs composite materials including SPC core layers, wear-resistant layers, and decoration layers to create a floorboard that combines the visual appeal of marble with the lightweight properties of plastic-composite materials
2Reliability
If traditional marble imitation tiles are used, then aesthetic appearance is improved, but installation complexity and cost increase
Solution Approach 1:
The floorboard is segmented into multiple functional layers (wear-resistant layer, decoration layer, SPC core layers) that can be manufactured separately and assembled through locking mechanisms, simplifying installation compared to traditional tile laying with grout
Solution Approach 2:
The floorboard incorporates self-locking edge mechanisms and click-lock systems that enable installation without professional grout application skills, allowing DIY installation and reducing labor complexity
3Ease of operation
If grout is used to fill gaps between tiles, then tile laying is enabled, but aging and failure occur due to thermal expansion differences
Solution Approach 1:
The invention extracts and eliminates the grout component from the flooring system by using continuous SPC material with groove designs that visually simulate grout lines, removing the source of thermal expansion compatibility problems
Solution Approach 2:
The wear-resistant layer and decoration layer act as intermediaries that provide the visual appearance of grout lines through groove designs while maintaining the continuity and thermal compatibility of the SPC material underneath
4Ease of operation
If SPC floorboard is used, then lightweight and easy installation are achieved, but aesthetic variety and high-end decoration effects are insufficient
Solution Approach 1:
The decoration layer incorporates locally varied marble patterns, veining, and textures that provide high-end aesthetic variety in specific areas, while the overall SPC structure maintains lightweight and easy installation properties
Solution Approach 2:
The multi-layer composite structure combines SPC material with specialized wear-resistant and decoration layers to achieve both the aesthetic variety of marble flooring and the installation ease of modern composite flooring
5Reliability
If multi-layer co-extrusion is used to create marble tile appearance, then aesthetic appearance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple manufacturing functions into a single co-extrusion process that simultaneously forms the wear-resistant layer, decoration layer, and SPC core layers with groove designs, reducing the number of separate manufacturing steps
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 lightweight, cost-effective, and aesthetically appealing SPC floorboard with enhanced weather resistance, wear resistance, and simplified installation, meeting high-end decoration demands and environmental sustainability.
Implementation Method 1
a second SPC substrate layer being a foamed SPC layer
Data Source
AI summary
A marble tile-imitating stone plastic composite (SPC) floorboard includes a wear-resistant layer, a decoration layer, a first SPC substrate layer, a second SPC substrate layer being a foamed SPC layer and a third SPC substrate layer. The wear-resistant layer, the decoration layer, the first SPC substrate layer, the second SPC substrate layer and the third SPC substrate layer are arranged in sequence from top to bottom. The first SPC substrate layer includes 12-20 wt. % of a polyvinyl chloride (PVC) resin, 12-20 wt. % of a silicone-modified acrylic resin and 50-70 wt. % of calcium carbonate. The floorboard is provided with a groove configured to recess downward from the wear-resistant layer, and a lowest point of the groove is not lower than a middle point of the first SPC substrate layer along a thickness direction of the first SPC substrate layer. The groove is configured to imitate a tile grout aesthetic effect.