Flooring Element With PET Wear Layer and Cork Damping
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Solution Overview
Problem
Existing laminate floor elements lack high elasticity and optimal usage properties, which are essential for improved application and durability.
Innovation Solution
A floor element with a carrier board and a multi-layer wear coating comprising a damping layer, a decorative layer made of thermoplastic materials like polyethylene terephthalate (PET) or polypropylene (PP), and a wear layer, along with a backing for dimensional stability and moisture barrier, providing high elasticity and resistance to indentation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a multi-layer wear coating with damping layer is applied to the carrier board, then elasticity and resistance to indentation are improved, but device complexity increases
Solution Approach 1:
The patent applies a multi-layer composite coating structure consisting of a damping layer (first layer) and a wear layer (second layer) on the carrier board. Each layer serves a specific function: the damping layer provides elasticity and indentation resistance, while the wear layer provides surface durability. This composite structure resolves the contradiction by combining materials with complementary properties to achieve both high strength and controlled complexity.
Solution Approach 2:
The coating is segmented into distinct functional layers: a damping layer made of thermoplastic material (PET or PP) for elasticity, and a wear layer for surface protection. This segmentation allows each layer to be optimized for its specific function, achieving superior indentation resistance through the damping layer while maintaining a relatively simple overall structure that can be manufactured efficiently.
2Object-affected harmful factors
If thermoplastic materials (PET/PP) are used instead of PVC, then environmental safety and elasticity are improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies precise parameter ranges for the thermoplastic damping layer, including thickness (0.3-3.0 mm) and density (30-800 kg/m³), to optimize both environmental safety and manufacturing precision. By defining these parameters clearly, the patent enables controlled manufacturing processes that can achieve the desired precision when working with thermoplastic materials, while avoiding the harmful effects of PVC and plasticizers.
3Strength
If the damping layer thickness is increased to 0.3-3.0 mm, then elasticity is improved, but loss of substance increases
Solution Approach 1:
The patent provides a thickness range (0.3-3.0 mm) for the damping layer, allowing manufacturers to apply the minimum necessary thickness (0.3 mm) to achieve adequate elasticity for most applications, thereby reducing material consumption. The upper limit (3.0 mm) is provided for cases where higher elasticity is specifically required, enabling a balanced approach that minimizes material use while meeting performance requirements.
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 combination of materials enhances the floor element's elasticity and stability, offering improved application and usage properties, including resistance to indentation and environmental safety without using PVC or plasticizers.
Implementation Method 1
The floor element according to the invention very good application and usage properties, in particular high elasticity
Implementation Method 2
The damping layer has a thickness of 0.8 mm to 3.5 mm, preferably 1.0 mm to 3.0 mm
Implementation Method 3
The useful coating comprises at least one damping layer (15), one decorative layer (16) and one wear layer (17)
Data Source
AI summary
Floor element which has a carrier panel (3) with a top-side, multiple-layer use coating (4). The use coating (4) comprises a damping layer (15), a decorative layer (16) and a wear layer (17), wherein the wear layer (17) is composed of a thermoplastic plastic on the basis of polyethylene terephthalate (PET) and/or polypropylene (PP). The damping layer (15) is preferably composed of a highly compressed granulate material, in particular of cork. A sealing layer (18) comprising a varnish on polyurethane basis is provided on the top side of the wear layer (17).