Panel for forming a floor covering
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Solution Overview
Problem
Existing floor panels made of thermoplastic materials, particularly vinyl-based panels, suffer from significant shrinkage and expansion issues due to temperature changes, leading to gaps and instability, and existing solutions either lack flexibility or have poor dimensional stability and appearance variability.
Innovation Solution
The use of a panel structure comprising two layers of strewn and pressed thermoplastic granulate enclosing a glass fiber layer, preferably a glass fiber fleece, with individual fibers of specific lengths and concentrations, and a thermoplastic material with improved adherence and thermal properties, along with a transparent wear layer for enhanced stability and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If panels are made of thermoplastic material with high material density and multiple prefabricated layers, then the panels achieve good adhesion and structural integrity, but they suffer from strong shrinkage and expansion under temperature influence
Solution Approach 1:
The patent uses a composite structure with at least two thermoplastic layers and one glass fiber layer. The glass fiber layer (3-15% by weight) is embedded within the thermoplastic matrix to create a composite material that maintains the adhesion benefits of thermoplastic while significantly reducing thermal expansion and shrinkage. This composite approach resolves the contradiction by combining materials with complementary properties.
Solution Approach 2:
The patent modifies the compositional parameters of the panel by incorporating glass fiber reinforcement at specific concentrations (3-15% by weight). This parameter change transforms the purely thermoplastic structure into a reinforced composite, altering the thermal response characteristics while maintaining structural integrity. The glass fiber content is optimized to balance dimensional stability with flexibility and adhesion.
2Stability of the object's composition
If glass fiber layer is added to increase dimensional stability, then shrinkage and expansion are reduced, but the flexibility and adaptability to uneven surfaces decrease
Solution Approach 1:
The patent applies local quality by distributing the glass fiber layer specifically within the thermoplastic structure rather than making the entire panel rigid. The glass fiber concentration (3-15% by weight) is optimized to provide dimensional stability where needed while maintaining overall panel flexibility. This localized reinforcement approach allows the panel to resist thermal deformation while still adapting to surface unevenness.
Solution Approach 2:
The composite structure of thermoplastic layers combined with glass fiber reinforcement creates a material that exhibits both rigidity and flexibility. The thermoplastic matrix provides flexibility and adaptability, while the embedded glass fiber layer provides dimensional stability. This composite approach resolves the contradiction between rigidity and flexibility.
3Productivity
If traditional injection molding process is used to produce floor panels, then production is achieved, but the precision is inferior and the process is time-consuming with limited appearance variation
Solution Approach 1:
The patent segments the panel structure into distinct layers (at least two thermoplastic layers and one glass fiber layer) that can be manufactured and assembled with higher precision. This layered approach allows for better control of each individual layer's properties and thickness, improving overall manufacturing precision compared to monolithic injection molding.
Solution Approach 2:
The use of composite materials with embedded glass fiber layers enables more precise control over panel properties during manufacturing. The composite structure allows for better dimensional control and reduced warping compared to traditional injection-molded panels, achieving superior 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 configuration significantly reduces dimensional changes, provides better stability and locking mechanisms, and maintains quality coupling of panels, ensuring a more stable and durable floating floor covering.
Implementation Method 1
The panels of the state of the art show the disadvantage that they are strongly subjected to shrinkage and expansion, or even bending, under the influence of temperature
Implementation Method 2
two layers substantially consisting of a strewn and pressed granulate
Data Source
AI summary
A panel including at least a substrate of thermoplastic material and a top layer with a printed decor and a translucent or transparent wear layer. The substrate includes three layers, including a lowermost layer, a central layer and an uppermost layer, all made from thermoplastic material, where the thermoplastic material of the central layer is more rigid than the thermoplastic material of the lower most layer and the uppermost layer.