Plastic Flooring Substrate Hot Pressing Eliminates Glue

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional plastic flooring made from foaming materials has poor production efficiency and environmental pollution due to the use of glue for adhering a printing layer.

Innovation Solution

The equipment and method for making a substrate of plastic flooring include an extrusion unit, thickness regulating unit, and rolling apparatus, which foam molds, cools, and hot presses a foaming sheet with a printing layer and abrasion resistant layer to create an environmentally friendly product.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If glue is used to adhere the printing layer to the foaming sheet, then the layers can be connected, but production efficiency decreases and environmental pollution increases

Engineering Contradiction:

Improvelayer connectionVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention extracts and eliminates the glue component from the manufacturing process. Instead of using adhesive to bond the printing layer to the foaming sheet, the patent employs a hot press welding mechanism that directly fuses the layers together through heat and pressure, completely removing the need for separate adhesive materials and application steps.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention replaces the chemical bonding mechanism (glue adhesion) with a thermal-mechanical bonding mechanism (hot press welding). The heating unit provides thermal energy to soften the materials, while the pressing unit applies mechanical pressure to fuse the printing layer with the foaming sheet, creating a strong bond without chemical adhesives.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If glue is used to adhere the printing layer to the foaming sheet, then the layers can be connected, but environmental pollution increases

Engineering Contradiction:

Improvelayer connectionVSAvoidenvironmental pollution

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention converts the potential harm of chemical adhesives into a beneficial thermal-mechanical bonding process. By using heat and pressure instead of chemical glue, the process transforms a polluting chemical operation into a cleaner physical process that eliminates harmful emissions and waste associated with adhesive chemicals.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Stability of the object's composition

If conventional foaming material is used, then the flooring is flexible, but production efficiency is poor

Engineering Contradiction:

ImproveflexibilityVSAvoidproduction efficiency

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The invention performs preliminary actions by pre-heating the foaming sheet and printing layer before bonding. The heating unit softens these materials in advance, making them more pliable and easier to bond together. This preliminary thermal preparation eliminates the need for slow-setting adhesives and enables immediate bonding, significantly improving production efficiency while preserving the flexibility of the foaming material.

Inventive Principle:

Principle #10Preliminary action

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 approach enhances production efficiency and reduces environmental pollution by integrating the layers through a hot pressing process, resulting in a more sustainable and efficient manufacturing method for plastic flooring.

Implementation Method 1

a heating unit heats the foaming sheet, the printing layer, and the abrasion resistant layer so that the foaming sheet, the printing layer, and the abrasion resistant layer are connected together

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

a cooler configured to cool the foaming sheet and to regulate a thickness of the foaming sheet

Methodology Applied

Scientific EffectCooling: Cooling

Implementation Method 3

the press roller at least includes a contacting roller and a pressing roller, wherein the contacting roller is configured to roll the foaming sheet, the printing layer, and the abrasion resistant layer together

Methodology Applied

Scientific EffectHot pressing:

Data Source

PatentUS10870266B2Equipment and method of making substrate of plastic flooring

Publication Date: 2020.12.22 WUXI BOYU PLASTIC MACHINERY

AI summary

Equipment of making a substrate of plastic flooring contains: an extrusion unit, a thickness regulating unit, and a rolling apparatus. The extrusion unit includes an outlet, and the thickness regulating unit including an inlet, a channel, and a cooler. The rolling apparatus includes a first roller, a second roller, and a press roller. The press roller at least includes a contacting roller and a pressing roller, wherein the contacting roller is configured to roll a foaming sheet, a printing layer, and an abrasion resistant layer. Furthermore, a heating unit heats the foaming sheet, the printing layer, and the abrasion resistant layer so that the foaming sheet, the printing layer, and the abrasion resistant layer are connected by using the pressing roller.