Rigid Multilayer Tile Composite Structure for Dimensional Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional building materials, such as wood flooring and PVC tiles, face issues with moisture sensitivity, dimensional instability, and environmental concerns due to the use of adhesives and plasticizers, while wood-plastic composites lack strength and durability.
Innovation Solution
A rigid multilayer tile structure comprising a foam cushion layer and a reinforcing layer, formed without adhesives, using polymer resins and minimal plasticizers, which provides lightweight, high strength, and excellent soundproofing properties, and is environmentally friendly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If wood flooring materials are used, then natural aesthetic appearance is achieved, but moisture resistance and dimensional stability deteriorate
Solution Approach 1:
The invention uses a composite structure combining a rigid core layer (MDF/HDF) with foam layers and HPM sheets. This composite material approach allows the tile to achieve both the aesthetic appearance of wood and the dimensional stability of engineered materials, resolving the contradiction between natural look and stability.
2Strength
If laminated flooring materials are used, then surface strength is improved, but moisture resistance deteriorates
Solution Approach 1:
The patent employs a multi-layer composite structure where the rigid core provides surface strength while the foam layers and HPM sheets provide moisture resistance. This composite approach allows simultaneous achievement of both surface strength and moisture resistance that cannot be obtained with single materials.
3Object-affected harmful factors
If PVC tiles are used, then moisture resistance is improved, but hardness and strength deteriorate
Solution Approach 1:
The invention combines PVC-based HPM sheets (providing moisture resistance) with MDF/HDF rigid core layers (providing hardness and strength). This composite structure allows the tile to achieve both moisture resistance from PVC and structural strength from wood-based materials, resolving the contradiction between these two properties.
4Strength
If adhesive bonding is used for layer lamination, then bonding strength is improved, but environmental friendliness deteriorates
Solution Approach 1:
The patent removes adhesive bonding from the layer lamination process, instead using mechanical interlocking and friction-based bonding between layers. This extraction of the harmful adhesive element maintains bonding strength through alternative mechanisms while significantly improving environmental friendliness by eliminating VOC emissions from adhesives.
5Weight of moving object
If foam cushion layer is added, then weight is reduced and cushioning feeling is improved, but surface strength deteriorates
Solution Approach 1:
The patent combines a lightweight foam cushion layer with a rigid MDF/HDF core layer and HPM surface layers. This composite structure allows the foam to provide weight reduction and cushioning while the rigid layers maintain surface strength, resolving the contradiction between lightness and strength.
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
Disclosed herein are a rigid tile including a foam cushion layer and a reinforcing layer, and a production method thereof.