Pozzolan SPC Flooring Layer Structure for Impact and Water Resistance
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Solution Overview
Problem
Existing flooring materials, such as wooden and laminate, suffer from issues like scratches, cracks, flammability, high contraction and expansion, water damage, and poor assembly, lacking eco-friendliness and durability, especially in environments requiring impact resistance, flame retardancy, and sound absorption.
Innovation Solution
A flooring material composed of a stone plastic composite (SPC) with layers including a base material layer, color film layer, wear layer, UV resistant layer, and pad layer, utilizing pozzolan and PVC, designed with a click-lock structure for easy installation and featuring non-harmful emissions, low contraction, and enhanced durability, impact resistance, and steam-cleanability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wooden flooring material is used, then it provides natural appearance and warmth, but it causes scratches, cracks, and deformation when physical impacts are applied
Solution Approach 1:
The patent uses Stone Plastic Composite (SPC) technology to create a flooring material that combines stone powder, PVC, and other additives to form a composite structure. This composite material provides both the natural appearance of wood and the durability to resist scratches, cracks, and physical impacts, resolving the contradiction between aesthetic appeal and mechanical strength.
2Object-affected harmful factors
If wooden flooring material is used, then it provides natural aesthetic, but it is flammable and easy to be burnt by fire
Solution Approach 1:
The patent changes the material composition parameters by replacing natural wood with SPC composite materials that have inherently lower flammability. The formulation includes specific ratios of stone powder, PVC, and additives that create a fire-resistant material while maintaining aesthetic properties, thus resolving the contradiction between natural appearance and fire safety.
3Stability of the object's composition
If wooden flooring material is used, then it provides natural look, but it has high contraction and expansion rates causing lifting in summer
Solution Approach 1:
The patent modifies the material composition to include SPC components with low thermal expansion coefficients. By adjusting the formulation of stone powder, PVC, and additives, the material achieves dimensional stability that minimizes contraction and expansion under temperature and humidity changes, preventing lifting while maintaining the natural aesthetic appearance.
4Object-affected harmful factors
If laminate flooring material is used, then it provides high stain resistance and corrosion resistance, but the surface is damaged when water continuously permeates
Solution Approach 1:
The patent uses SPC composite technology with a core layer containing stone powder and PVC, combined with protective wear layers. This composite structure provides both stain resistance and superior water resistance, as the stone plastic composite core does not absorb water like traditional laminate, preventing surface damage while maintaining aesthetic properties.
5Ease of manufacture
If laminate flooring material is used, then it provides reasonable cost and high corrosion resistance, but it has poor assembling performance upon construction
Solution Approach 1:
The patent divides the flooring material into modular components with interlocking mechanisms, allowing for easy assembly and installation. The segmentation of the structure enables simple connection between planks, improving assembling performance and installation efficiency while maintaining the cost-effectiveness and corrosion resistance of SPC materials.
Data Source
AI summary
The present invention relates to a flooring material including: a base material layer as a stone plastic composite (SPC) core; a color film layer formed on top of the base material layer to provide a given color and pattern; a wear layer formed on top of the color film layer to provide a corrosion resistance; a UV resistant layer formed on top of the wear layer to provide surface protection; and a pad layer formed on the underside of the base material layer to provide shock absorption and sound absorption.