Rail Vehicle Floor Composite Material for Weight Reduction
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Solution Overview
Problem
Current floor coverings in rail vehicles are heavy, inflexible, and prone to rapid wear due to their thickness and material properties, while also failing to meet fire protection standards and requiring halogen-based materials.
Innovation Solution
A composite material comprising a film with layers of textile fabric, adhesive, thermoplastic polyurethane backing, printing ink, transparent layer, and lacquer applied to a base plate, resulting in a thin, lightweight, and highly abrasion-resistant surface that meets fire protection standards without halogen-based materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rubber mats of 2.5 to 5 mm thickness are used for floor coverings, then wear resistance is provided, but the floor coverings become heavy and inflexible
Solution Approach 1:
The patent applies a thin film structure (total thickness < 1 mm) with multiple functional layers including a thermoplastic polyurethane base layer, textile fabric reinforcement, and protective top layers. This thin film design replaces the conventional thick rubber mat (2.5-5 mm) while maintaining durability through the synergistic combination of multiple specialized layers, each contributing specific properties such as abrasion resistance, flexibility, and fire protection.
Solution Approach 2:
The patent employs a composite material structure consisting of multiple layers with different functions: a thermoplastic polyurethane base layer for flexibility and adhesion, a textile fabric layer for reinforcement and abrasion resistance, an adhesive layer for bonding, and protective top layers (printing ink, clear layer, lacquer) for surface durability. This composite approach allows each layer to contribute its specific strengths, achieving overall superior wear resistance and flexibility compared to homogeneous rubber mats.
2Duration of action of stationary object
If thick rubber mats are used to ensure durability, then protection is provided, but the floor coverings require frequent replacement due to rapid wear
Solution Approach 1:
The patent uses a multi-layer thin film structure where the outermost layers (clear layer and lacquer layer) provide enhanced abrasion resistance and protection, while the underlying thermoplastic polyurethane base layer and textile fabric provide structural integrity and flexibility. This layered protection system extends service life by distributing wear across multiple layers, with the hardwearing top layers protecting the softer base materials.
Solution Approach 2:
The composite structure combines materials with complementary properties: the thermoplastic polyurethane base layer provides flexibility and shock absorption, the textile fabric layer (e.g., polyester or polyamide) provides tensile strength and abrasion resistance, and the protective top layers (clear layer and lacquer) provide surface hardness and chemical resistance. This combination creates a floor covering that resists wear while maintaining flexibility and extending service life.
3Reliability
If conventional rubber mats are used for floor coverings, then basic protection is provided, but fire protection standards are not met and halogen-based materials are required
Solution Approach 1:
The patent specifies that the thermoplastic polyurethane base layer has a melting point of at least 150°C, which is a critical parameter change that enables fire protection compliance. This elevated melting point prevents the material from melting or deforming under fire conditions, allowing it to meet fire safety standards without requiring halogen-based flame retardants. The material's inherent thermal stability replaces the need for harmful chemical additives.
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 composite material achieves significant weight reduction, improved flexibility, and enhanced abrasion resistance while adhering to fire safety standards, offering energy savings and extended durability.
Implementation Method 1
b) at least one adhesive
Implementation Method 2
the composite material according to the invention is characterized by particularly advantageous abrasion resistance
Implementation Method 3
d) at least one printing ink layer
Implementation Method 4
e) at least one clear layer and f) at least one lacquer layer
Data Source
AI summary
The present invention relates to a composite material, wherein a film is applied to a base plate, the film comprising at least the following layers in this order: a) at least one textile fabric, b) at least one adhesive, c) at least one support layer based on a thermoplastic polyurethane, d) at least one printing ink layer, e) at least one transparent layer and f) at least one lacquer layer, a method for its production, and the use of this composite material as a floor covering, in particular in a rail vehicle.