Glue-Free PVC Floorboard Warping Control
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Solution Overview
Problem
Glue-free floorboards face issues with uneven ground installation, warping due to temperature changes, and contraction-expansion problems, which affect their stability and installation success.
Innovation Solution
A glue-free antislip plastic floorboard composition comprising a wear-resistance layer, PVC medium material layers, glass fiber, and a PVC antislip layer, with specific material ratios and a manufacturing process involving baking and tempering, balances flexibility and slip resistance, and controls size changes through the addition of glass fiber and optimized tempering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the floorboard uses multiple layers of raw materials with different compositions to achieve flexibility, then the flexibility is improved, but the warping resistance deteriorates due to temperature change stresses
Solution Approach 1:
The patent applies parameter changes by precisely controlling the composition ratios of PVC resin (34.7-40%), calcium carbonate (34-40%), and plasticizer (24-24.9%) in the PVC bottom material layer. This optimization balances flexibility and dimensional stability, allowing the floorboard to adapt to ground irregularities while resisting warping from temperature-induced stresses between different materials.
Solution Approach 2:
The patent uses composite materials by combining multiple PVC layers with different compositions - the PVC medium material layer (13-15.42% PVC resin, 74-75.55% calcium carbonate) provides rigidity and wear resistance, while the PVC bottom material layer (34.7-40% PVC resin, 24-24.9% plasticizer) provides flexibility. This multi-layer composite structure achieves both flexibility and warping resistance simultaneously.
2Ease of operation
If the floorboard is made completely flat to fit uneven ground, then the installation ease is improved, but the contraction-expansion control deteriorates
Solution Approach 1:
The patent applies local quality by creating different surface characteristics in different layers. The PVC bottom material layer has high plasticizer content (24-24.9%) providing flexibility for adapting to ground irregularities, while the PVC medium material layer has low plasticizer content (10-11%) providing dimensional stability for contraction-expansion control. Each layer performs its specific function locally.
3Strength
If the floorboard uses high calcium carbonate content to reduce cost and improve rigidity, then the manufacturing cost is reduced and strength is improved, but the flexibility deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the PVC material into two distinct layers with different functions. The PVC medium material layer contains high calcium carbonate (74-75.55%) for rigidity and wear resistance, while the PVC bottom material layer contains lower calcium carbonate (34-40%) but high plasticizer (24-24.9%) for flexibility. This segmentation allows each layer to optimize its properties without compromising the other.
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 solution ensures the floorboard remains flat and stable on uneven surfaces, prevents warping, and effectively manages contraction and expansion, reducing installation costs and maintaining performance over time without the need for glue or locks.
Implementation Method 1
The floorboard has a contraction-expansion problem. Any plastic floorboard can produce contraction and expansion. How to effectively control the size change of the floorboard, and how to try to reduce the gap in a long-term using process of the floorboard, these problems are becoming very critical.
Implementation Method 2
A manufacturing method of a glue-free antislip plastic floorboard comprises the following steps of. 1) laying from a top to a bottom a wear-resistance layer (2), a printing layer (3), a PVC medium material layer (4), a glass fiber (5), a PVC medium material layer (6), a PVC bottom material layer (7) and a PVC antislip layer (8); 2) baking after laying, a baking temperature being from 125 to 130 degrees celsius... 4) performing a tempering process, a tempering temperature being greater than 95 degrees Celsius.
Data Source
Figure 1
AI summary
A glue-free antislip plastic floorboard and a manufacturing method thereof, comprising from a top to a bottom a wear-resistance layer, a printing layer, a polyvinyl chloride (PVC) medium material layer, glass fiber, a PVC medium material layer, a PVC bottom layer and a PVC antislip layer. Component composition of PVC medium material: a weight percentage of PVC resin is 13-15.42%, a weight percentage of calcium carbonate is 74-75.55%, a weight percentage of a plasticizer is 10-11%, a weight percentage of a stabilizer is 0.25-0.28%, and a weight percentage of black carbon is 0.2-0.3%. Component composition of PVC bottom material: a weight percentage of the PVC resin is 34.7-40%, a weight percentage of the calcium carbonate is 34-40%, a weight percentage of the plasticizer is 24-24.9%, a weight percentage of the stabilizer is 0.7-0.8%, and a weight percentage of the black carbon is 0.4-0.5%. An overall flexibility thereof is good, slip resistance of a back side reaches balanced, warping is not easy, and an overall shrinkage and expansion level is more superior.