Rigid Multilayer Surface Covering with Sandwiched Reinforcement
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Solution Overview
Problem
Existing decorative surface coverings, such as those made from thermoplastic materials like PVC, face challenges in achieving both rigidity and flexibility, especially when exposed to temperature variations, and lack sufficient resistance to compression and traction.
Innovation Solution
A rigid multilayer decorative surface covering with a sandwiched reinforcement composite layer, comprising a thermoplastic polymer matrix and fibre-based reinforcement layers on both surfaces, which improves structural stability, thermal stability, and resistance to compression and traction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcement layers are added to increase rigidity, then the stiffness of the surface covering is improved, but the flexibility is reduced
Solution Approach 1:
The patent applies composite materials by combining a thermoplastic polymer matrix with fibre-based reinforcement layers (such as glass fibres, PP, PET, or unplasticized PVC) to create a sandwiched reinforcement composite layer. This composite structure provides both rigidity from the reinforcement fibres and flexibility from the thermoplastic matrix, resolving the contradiction between stiffness and flexibility.
Solution Approach 2:
The reinforcement layers are strategically positioned at specific locations within the surface covering structure - namely in the base layer and backing layer - to provide localized reinforcement where needed. This allows the surface covering to maintain high stiffness in structural areas while preserving flexibility in other regions, addressing the contradiction through spatially differentiated properties.
2Strength
If the surface covering thickness is increased to improve durability and resistance to compression and traction, then the strength is improved, but the weight increases
Solution Approach 1:
The patent uses composite materials with high strength-to-weight ratio, specifically fibre-based reinforcement layers (glass fibres, PP, PET, unplasticized PVC) combined with a thermoplastic polymer matrix. These composites provide enhanced resistance to compression and traction forces while maintaining relatively low weight compared to using thicker or denser single-material structures.
Solution Approach 2:
The surface covering is segmented into multiple functional layers including a base layer with reinforcement layers, a decorative layer, and a backing layer with reinforcement layers. This segmentation allows each layer to be optimized for its specific function - the reinforcement layers provide strength against compression and traction, while the overall structure maintains acceptable weight through efficient layer distribution.
3Ease of operation
If thermoplastic material is used to maintain flexibility, then the flexibility is improved, but the thermal stability is reduced when exposed to temperature variations
Solution Approach 1:
The patent combines thermoplastic polymer matrix with fibre-based reinforcement layers to create a composite structure where the fibres provide thermal stability and the thermoplastic matrix maintains flexibility. The reinforcement layers act as thermal stabilizers while the thermoplastic component preserves the necessary flexibility for operation, resolving the contradiction between flexibility and thermal stability.
Solution Approach 2:
The reinforcement layers are positioned in the base layer and backing layer to provide localized thermal stability where temperature variations have the most impact. This allows the surface covering to maintain thermal stability in structural areas while preserving flexibility in the overall structure, addressing the contradiction through spatial differentiation of thermal and mechanical properties.
Data Source
AI summary
A rigid multilayer decorative surface covering is proposed. The surface covering has a thickness and comprises a sandwiched reinforcement composite layer comprising a thermoplastic polymer matrix having a top and a bottom surface, the sandwiched reinforcement composite layer comprising reinforcement layers on the top and bottom surfaces. The sandwiched reinforcement composite layer has a thickness comprised in the range from 25% to 85% of the thickness of the rigid decorative surface covering. A method for manufacturing the rigid multilayer decorative surface covering is also disclosed.