Crosslinked Polyolefin Foam Floor Structure for Acoustic Insulation
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Solution Overview
Problem
Existing multilayer floor and wall coverings struggle to achieve both adequate acoustic insulation, specifically sound attenuation of at least 18 dB according to the NF EN ISO 717-2 standard, and maintain residual puncture resistance values below 0.25, while existing solutions often complicate installation with additional foam layers.
Innovation Solution
A multilayer structure incorporating a transparent wear layer, a decorative layer, a backing layer made from plasticized and loaded polyvinyl chloride, and a crosslinked polyolefin foam layer with specific mechanical characteristics, such as a tensile modulus greater than 5 MPa and a flexural modulus between 10 MPa and 20 MPa, optimized for acoustic insulation and puncture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the thickness of the foam layer is increased to improve sound attenuation, then acoustic insulation properties are improved, but residual indentation resistance deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the foam layer thickness (0.5-2.0 mm) and density (60-120 kg/m³) to achieve optimal balance between sound attenuation and puncture resistance. The cross-linking degree of the polyolefin foam is also controlled to modify its mechanical properties, allowing it to provide acoustic insulation while maintaining sufficient structural resistance to indentation.
Solution Approach 2:
The patent uses composite materials by combining the foam layer with a reinforced backing layer containing a textile reinforcement (mesh or fabric). This composite structure allows the foam to provide acoustic insulation while the reinforcement layer maintains puncture resistance, resolving the contradiction between soft acoustic properties and hard mechanical resistance.
2Object-affected harmful factors
If a separate foam layer is added for acoustic insulation, then sound attenuation is improved, but installation complexity increases
Solution Approach 1:
The patent merges the foam layer with the backing layer into a single integrated component. The foam layer is bonded to the backing layer (which may include textile reinforcement) to form a unified assembly that is installed as one piece, eliminating the need for separate foam layer installation and reducing overall installation complexity while maintaining acoustic insulation performance.
3Object-affected harmful factors
If a foam layer is added for acoustic insulation, then sound attenuation is improved, but installation time increases
Solution Approach 1:
By integrating the foam layer with the backing layer into a single pre-bonded assembly, the patent enables installation as one unified component rather than multiple separate layers. This merging reduces the number of installation steps and adhesive applications required, thereby reducing installation time while preserving the acoustic insulation benefits of the foam layer.
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 structure achieves the desired acoustic attenuation of at least 18 dB while maintaining a residual puncture resistance value of less than 0.25, with improved installation efficiency by integrating the foam layer within the multilayer structure.
Implementation Method 1
a foam layer, bonded to the backing layer, giving acoustic insulation properties to the structure
Implementation Method 2
the foam layer is a cross-linked polyolefin foam layer... giving acoustic insulation properties... maintaining a residual indentation resistance value of less than 0.25
Data Source
Figure 1~2
AI summary
The invention relates to a multilayer structure (1) for the production of a floor or wall covering, the structure comprising: - a first assembly (E) comprising successively at least: * a transparent wear layer (E1) made from polyvinyl chloride; * a decorative layer (E2) bonded to the wear layer (E1); * a backing layer (E3), bonded to the decorative layer (E2), made from plasticized and filled polyvinyl chloride; - a foam layer (2), bonded to the backing layer (E3), giving acoustic insulation properties to the structure, and having a lower face intended to be in contact with the floor or wall.According to the invention: - the first assembly (E) comprises a tensile modulus for 1% elongation greater than 5 MPa, and a flexural modulus at 3.5% between 10 MPa and 20 MPa, measured according to ISO 178:2019; - the foam layer (2) is a crosslinked polyolefin foam layer, having a thickness between 0.5 mm and 2 mm, and a density between 60 kg/m3 and 120 kg/m3.