Plastic Flooring Backing via Sprayed Strap Molding
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Solution Overview
Problem
Existing methods for manufacturing plastic flooring with backing result in noisy surfaces when walked upon and require the use of coating glue, complicating the manufacturing process with flexible plastic straps and inefficient production.
Innovation Solution
A method involving extrusion molding, pressing, and a spraying mechanism to form a backing on the substrate using PVC or PU materials in spaced strap or spot shapes, controlled by an electric system to prevent noise and streamline production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a continuous backing is formed on the substrate, then noise reduction is improved, but manufacturing complexity increases due to glue coating requirements
Solution Approach 1:
The backing is divided into multiple discrete plastic straps or spots rather than forming a continuous layer. These segmented elements are positioned at specific intervals on the substrate bottom, eliminating the need for glue coating while reducing noise through distributed cushioning points.
Solution Approach 2:
The glue coating step is completely removed from the manufacturing process. The plastic straps or spots are directly formed on the substrate without requiring any adhesive layer, simplifying the manufacturing process while maintaining noise reduction functionality.
2Object-affected harmful factors
If multiple plastic straps are engaged in receiving grooves, then noise reduction is improved, but manufacturing complexity increases
Solution Approach 1:
The backing formation is merged with the substrate manufacturing process. The plastic straps or spots are formed directly on the substrate bottom in the same production line, eliminating separate assembly steps involving receiving grooves and manual engagement.
Solution Approach 2:
The substrate itself provides the positioning structure for the plastic straps through its bottom surface features. The straps are self-positioned on the substrate without requiring separate receiving grooves or manual alignment, enabling automated production.
3Strength
If coating glue is used on the backing, then adhesion is improved, but environmental friendliness deteriorates
Solution Approach 1:
The glue coating step is completely removed from the manufacturing process. The plastic straps or spots are directly formed on the substrate without requiring any adhesive layer, eliminating the environmental pollution associated with glue while maintaining structural integrity.
4Manufacturing precision
If manual assembly of plastic straps is used, then positioning precision is improved, but production efficiency deteriorates
Solution Approach 1:
The substrate bottom surface features automatically position the plastic straps during formation. The straps are self-aligned through the substrate's geometric features without requiring manual placement, enabling high-speed automated production while maintaining precise positioning.
Solution Approach 2:
Manual mechanical assembly is replaced with an automated spraying mechanism that forms the plastic straps directly on the substrate. The electric control system precisely controls the positioning and formation of each strap, achieving both high precision and high production efficiency.
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 method effectively reduces noise during walking and enhances production efficiency by eliminating the need for coating glue and allowing for precise placement of plastic materials, resulting in a quieter and more environmentally friendly manufacturing process.
Implementation Method 1
The melted plastic materials are separately sprayed onto the bottom of the substrate of the semi-finished plastic flooring by using the spraying mechanism of the drop plastic equipment
Implementation Method 2
the melted plastic materials form solidified plastic materials separately after solidifying
Implementation Method 3
the substrate is extrusion molded by using an extruder
Implementation Method 4
substrate, the printing layer, and the anti-abrasion layer are pressed together by using the pressing machine
Data Source
AI summary
A making plastic flooring having a backing contains: a body which has a substrate, a printing layer, and an anti-abrasion layer. A method of making the plastic flooring contains steps of: (A). producing a semi-finished plastic flooring, wherein the semi-finished plastic flooring has the substrate, the printing layer, and the anti-abrasion layer; (B). moving and positioning the semi-finished plastic flooring on a predetermined position of drop plastic equipment, wherein the semi-finished plastic flooring is faced upward; (C). molding the backing, wherein the backing material is melt and is spray onto a bottom of the substrate of the semi-finished plastic flooring by using drop plastic equipment, and the backing material is adhered on the bottom of the substrate of the semi-finished plastic flooring after being solidified; and (D). cutting, wherein the semi-finished plastic flooring having the backing is removed and is cut into a desired size, thus producing the body.