PVC Flooring Substrate Layer Hardness Gradient
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Solution Overview
Problem
Existing PVC flooring structures are prone to bending and deformation, leading to poor installation reliability and noise issues due to their susceptibility to ambient temperature and humidity changes, which affects flatness retention and installation efficiency.
Innovation Solution
A PVC flooring structure comprising a substrate layer with three sub-layers of varying hardness, where the flexible and correction layers with lower hardness are arranged on the outer sides and the strength layer in the middle, maintaining a hardness ratio of 1.05-1.10, providing stability and flexibility to counteract deformation forces and maintain flatness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional PVC flooring structure is used, then manufacturing simplicity is maintained, but the flooring is prone to bending and deformation
Solution Approach 1:
The substrate layer is segmented into three distinct sub-layers: a flexible layer, a strength layer, and a correction layer. Each sub-layer has specific thickness and hardness requirements, creating a composite structure that balances flexibility and stability while maintaining manufacturing feasibility through a multi-layer construction approach.
Solution Approach 2:
The flooring employs a composite structure combining multiple materials with different properties: the flexible layer provides adaptability, the strength layer provides structural support with 1.05-1.10 times the hardness of outer layers, and the correction layer compensates for deformations. This composite approach resolves the contradiction between manufacturing simplicity and flatness retention.
2Productivity
If the flooring thickness is reduced for easier installation, then installation efficiency improves, but the flooring becomes more prone to bending and deformation
Solution Approach 1:
Different regions of the flooring have different local properties: the outer flexible and correction layers have lower hardness for adaptability and deformation compensation, while the central strength layer has higher hardness (1.05-1.10 times greater) for structural stability. This local differentiation allows thin construction with improved installation efficiency while maintaining reliability through strategically placed high-hardness support.
Solution Approach 2:
The strength layer acts as a counterbalancing element with higher hardness positioned centrally between the two softer outer layers. This counterweight effect compensates for the reduced overall thickness, preventing bending and deformation while maintaining installation efficiency and reliability.
3Ease of operation
If the flooring has high flexibility for better foot feeling, then comfort improves, but the flooring may deform under environmental changes
Solution Approach 1:
The flooring implements local quality differentiation where the outer flexible layers provide comfort and adaptability for foot feeling, while the central strength layer with 1.05-1.10 times greater hardness provides shape stability and resistance to environmental deformation. This spatial differentiation of material properties simultaneously achieves both comfort and stability.
Solution Approach 2:
The invention changes the hardness parameter across different layers: outer layers have lower hardness for flexibility and comfort, while the central layer has higher hardness (1.05-1.10 times greater) for stability. This parameter gradient allows the flooring to provide both good foot feeling and resistance to environmental deformation.
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 enhances flatness retention and elasticity, allowing for rapid and economical installation while preventing locking failures and noise, providing a foot feeling similar to wooden flooring.
Implementation Method 1
the two sub-layers with lower hardness have better stability as well as the adaption of the stability, that is, they will not change their shape or will only scarcely change the shape while the ambient temperature and humidity changing; as a result that when the shape of the adjacent sub-layer of one sub-layer changing or tending to change, the said sub-layer limit and constrained the deformation of the said adjacent sub-layer by its stiffness, adjust to the deformation of the said adjacent sub-layer by its flexibility and further more counteract the force of the deformation
Data Source
AI summary
A polyvinyl chloride (PVC) flooring, includes a wear-resistant layer, a decorative layer and a substrate layer from top to bottom in order, wherein the substrate layer comprises a flexible layer, a strength layer and a correction layer from top to bottom in order and the hardness of the strength layer is 1.05-1.10 times that of the flexible layer and the correction layer.