Plastic Composite Flooring Folding Method for Seamless Transitions

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Solution Overview

Problem

Conventional methods for installing plastic composite flooring fail to seamlessly integrate with provisions like stair noses, baseboards, and T-moldings, leading to mismatches and additional installation burdens due to material differences and suboptimal transitions at flooring-wall junctions.

Innovation Solution

A method involving the application of heat and pressure using a thermal insulation layer and embossing dies to fold plastic composite flooring into desired shapes, allowing for seamless integration with provisions such as stair noses, baseboards, and T-moldings, eliminating the need for separate matching materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate provisions (stair noses, baseboards, T-moldings) are installed to accommodate substrate variations, then the flooring can adapt to different wall junctions and substrates, but material mismatches occur and installation complexity increases

Engineering Contradiction:

Improveadaptability to substrate variationsVSAvoidinstallation complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The flooring material itself is designed to perform multiple functions: it serves as both the walking surface and the transitional provision at wall junctions. By making the flooring adaptable to different substrate conditions through heating and forming, it eliminates the need for separate specialized provisions, thereby reducing installation complexity while maintaining adaptability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention merges the function of separate provisions (stair noses, baseboards, T-moldings) into the flooring material itself. Instead of installing distinct components for transitions, the flooring is directly formed to fit various substrate conditions, combining multiple functions into a single integrated solution

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If separate provisions made of different materials (solid milled wood, plaster, plastic) are used to fill gaps at wall junctions, then the flooring can accommodate various wall conditions, but texture and visual appearance mismatches occur

Engineering Contradiction:

Improveability to fill gaps at wall junctionsVSAvoidvisual appearance uniformity

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The invention uses the same flooring material for both the walking surface and the transitional provision at wall junctions. By forming the existing flooring material directly to fit the substrate, it ensures homogeneous appearance, texture, and color throughout, eliminating visual mismatches that occur when using different materials

Inventive Principle:

Principle #33Homogeneity

3Productivity

If conventional flooring installation methods are used without heating and forming, then the installation process is simpler and faster, but seamless transitions at wall junctions cannot be achieved

Engineering Contradiction:

Improveinstallation speedVSAvoidtransition quality at wall junctions

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The invention changes the physical parameters of the flooring material by applying heat, which makes the material pliable and formable. This temporary parameter change allows the flooring to be shaped to fit various substrate conditions, achieving seamless transitions while maintaining a relatively simple installation process

Inventive Principle:

Principle #35Parameter changes

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

Enables a seamless transition between flooring and wall junctions by forming the flooring into matching provisions on-site, ensuring uniformity in material, texture, and appearance, and simplifying the installation process by eliminating the need for multiple provision types.

Implementation Method 1

incorporating a thermal insulation layer between the plastic composite flooring and a heat generator, applying heat until reaching a heat transmission coefficient to allow the plastic composite flooring to become malleable

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

applying pressure to the heated section of the plastic composite flooring to form into a desired shape using a positive and negative embossing die fold on the top and bottom heated section

Methodology Applied

Scientific EffectPressure-induced deformation: Deformation

Data Source

PatentUS11485166B2Portable method and apparatus for folding plastic composite flooring

Publication Date: 2022.11.01 NEWGEN ENTERPRISES LLC

AI summary

A method of folding plastic composition flooring, including but not limited to LVP, LVT, SPC or WPC, to form a desired shape, such as stair noses, baseboards, quarter rounds, T-moldings, endcaps, or the like. The method includes the steps of incorporating a thermal insulation layer between the plastic composite flooring and a heat generator, applying heat until reaching a heat transmission coefficient to allow the plastic composite flooring to become malleable, removing the heat, applying pressure to the heated section of the plastic composite flooring to form into a desired shape using a positive and negative embossing die mold on the top and bottom heated section of the plastic composite flooring, and removing the embossing die-molds once the plastic composite flooring has cooled down to its initial temperature.