Rollable Wallpaper with Foam Layer for Uneven Surfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wallpapers fail to effectively smooth and cover uneven surfaces, such as those with structural glass fabrics or textured plaster, leading to visible bumps and poor processing characteristics, including breakage and damage during application.
Innovation Solution
A rollable wallpaper comprising a carrier layer and a foam layer, where the foam layer is arranged on one side of the carrier layer, providing a compression set of 15-25% after 24 hours and absorbing forces up to 2.0 N, allowing for easy application and concealment of surface irregularities without visible damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional paper wallpaper is used to cover structured glass fabric, then the wallpaper can be applied to the surface, but the structures of the glass fabric stand out on the new wall covering and the surface remains uneven
Solution Approach 1:
The wallpaper comprises a composite structure with a carrier layer (paper or non-woven fabric) and a foam layer (polymer-based). This composite design allows the foam layer to conform to and smooth over the uneven glass fabric surface while the carrier layer provides structural integrity and adhesion, thereby achieving both ease of application and surface smoothness.
Solution Approach 2:
The foam layer's compressibility and elasticity parameters enable it to adapt to the uneven surface topology. When applied, the foam deforms to fill gaps and cover protrusions on the glass fabric, creating a smooth visible surface while maintaining strong bonding through its viscoelastic properties.
2Manufacturing precision
If the wallpaper is made rigid to cover uneven surfaces effectively, then the smoothing capability improves, but the wallpaper becomes difficult to process and may break during application
Solution Approach 1:
The foam layer acts as a flexible shell that can deform and conform to uneven surfaces during application. This flexibility allows the wallpaper to be easily handled, rolled, and applied without breaking, while still providing effective surface smoothing when in place.
Solution Approach 2:
The wallpaper transitions from a flexible, easily processable state during application to a stable, smoothing state once applied. The foam layer's dynamic properties allow it to be manipulated during installation while maintaining structural integrity and smoothing function after application.
3Manufacturing precision
If the foam layer has high compression set to smooth surfaces, then the covering effect improves, but the wallpaper may become too soft and lose structural integrity
Solution Approach 1:
The combination of the strong carrier layer and the compressible foam layer creates a composite material with balanced properties. The carrier layer provides tensile strength and structural integrity, while the foam layer provides surface conforming and smoothing capabilities, achieving both surface covering effect and structural strength.
Solution Approach 2:
Different layers of the wallpaper have different local properties: the carrier layer is strong and rigid for structural support, while the foam layer is soft and compressible for surface conforming. This local differentiation of material properties allows the wallpaper as a whole to achieve both strength and surface covering effect.
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 achieves a smooth surface finish, preventing the visibility of underlying unevenness and ensuring the wallpaper remains intact during processing, thus enabling seamless application over structured glass fabrics or textured surfaces.
Implementation Method 1
the carrier layer and the foam layer optionally being detachably connected to one another, the foam layer having a compression set after 24 hours when compressed to 50% from 0% to 50%, and wherein the carrier layer absorbs a maximum force of more than 2.0 N
Implementation Method 2
the foam layer having a compression set after 24 hours when compressed to 50% from 0% to 50%
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2A~2B
AI summary
The rollable agent comprises a carrier layer, and a foam layer that is disposed on a first side of the carrier layer, where: a second side of the carrier layer faces away from a roughness surface; and the carrier layer and the foam layer are releasably connected to one another. The agent has a strength of 1.1-1.8 mm, and a weight of 300-350 g/m 2>. The foam layer has a strength of 0.8-1.1 mm, a density of 270 g/dm 3>, and a compression set of 15-25% during a compression of 50% after 24 hours. A second side of the carrier layer is provided for receiving other wallpaper and a painting. The rollable agent comprises a carrier layer, and a foam layer that is disposed on a first side of the carrier layer, where: a second side of the carrier layer faces away from a roughness surface; and the carrier layer and the foam layer are releasably connected to one another. The agent has a strength of 1.1-1.8 mm, and a weight of 300-350 g/m 2>. The foam layer has a strength of 0.8-1.1 mm, a density of 270 g/dm 3>, and a compression set of 15-25% during a compression of 50% after 24 hours. A second side of the carrier layer is provided for receiving other wallpaper, a painting, a dispersion plaster and/or other wall covering, where, if the agent is mounted on the surface, the second side of the carrier layer of the roughness surface is turned away. The carrier layer: has a strength of 0.35 mm and a weight of 130-170 g/m 2>; and receives a maximum force of more than 10 N. The carrier layer comprises a first paper layer, a first fabric layer, a first non-woven fabric layer, and/or a first plastic layer. The carrier layer further comprises a first non-woven fabric layer and a second non-woven fabric layer, where: the first non-woven fabric layer is connected with the second non-woven fabric layer; the first and second non-woven fabric layers comprise fibers; and the fibers for first and the second non-woven fabric layers consist of glass fibers, cellulose fibers, polyester fibers, natural fibers, and/or cellulose fibers. The first side and/or the second side of the carrier layer comprises a coating. An independent claim is included for a method for smoothing a roughness surface.