Layered PVC Floor Panel Structure to Prevent Edge Curling

Solution Overview

Problem

Luxury vinyl tiles (LVT) suffer from edge peaking and curling issues during packaging and transportation, particularly in cold climates, which compromise installation quality and aesthetics.

Innovation Solution

A dimensionally stable floor panel composition with a reinforced layer and a guide edge, featuring multiple polyvinyl chloride layers with varying filler and plasticizer content, a glass fiber section for stability, and a non-slip backing layer, along with tongue and groove connections for enhanced stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the floor panel is made thick and heavy with glass fiber veil to improve dimensional stability, then the dimension stability improves, but the ease of handling and installation deteriorates

Engineering Contradiction:

Improvedimensional stabilityVSAvoidease of handling

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The floor panel is divided into multiple functional layers including a wear layer, multiple base layers with different compositions, a glass fiber veil layer, and a backing layer. Each layer serves a specific purpose: the first base layer provides structural support, the glass fiber veil layer prevents curling and provides tensile strength, and the backing layer provides friction. This segmentation allows the panel to achieve dimensional stability without excessive overall thickness and weight.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The floor panel uses a composite structure combining different materials: polyvinyl chloride (PVC) with varying plasticizer content in different base layers, glass fiber veil for dimensional stability, and a non-slip backing material. The composite construction allows each material to contribute its optimal properties, achieving dimensional stability while maintaining manageable weight and handling characteristics through proper material selection and layer optimization.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If the floor panel uses a simple single-layer construction, then the ease of manufacture improves, but the dimensional stability deteriorates

Engineering Contradiction:

Improveease of manufactureVSAvoiddimensional stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The floor panel is divided into multiple functional layers including a wear layer, multiple base layers with different compositions, a glass fiber veil layer, and a backing layer. Each layer serves a specific purpose: the first base layer provides structural support, the glass fiber veil layer prevents curling and provides tensile strength, and the backing layer provides friction. This segmentation allows the panel to achieve dimensional stability without excessive overall thickness and weight.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The floor panel uses a composite structure combining different materials: polyvinyl chloride (PVC) with varying plasticizer content in different base layers, glass fiber veil for dimensional stability, and a non-slip backing material. The composite construction allows each material to contribute its optimal properties, achieving dimensional stability while maintaining manageable weight and handling characteristics through proper material selection and layer optimization.

Inventive Principle:

Principle #40Composite materials

3Shape

If the floor panel is made flat and smooth to improve visual appearance, then the aesthetic quality improves, but the fixation of placement deteriorates

Engineering Contradiction:

ImproveflatnessVSAvoidfixation of placement

Core Design Contradiction:

ShapeVSStability of the object's composition

Solution Approach 1:

The floor panel applies different surface qualities to different locations: the top wear layer maintains a smooth, flat surface for aesthetic purposes and visual appeal, while the bottom backing layer provides a non-slip textured surface for fixation and placement stability. This local differentiation of surface properties allows the panel to simultaneously achieve visual attractiveness and installation stability without compromise.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12559950B2Dimensionally stable floor panel

Publication Date: 2026.02.24 NOVALIS HLDG

AI summary

A floor panel is provided. The floor panel composition includes a wear layer and a base layer. The base layer includes a first base sections having a first composition of polyvinyl chloride, filler, and plasticizer, a second base sections having a second composition with a higher content of polyvinyl and plasticizer than the first composition, and a glass fiber section positioned between the first base section and the second base section.