Segmented Sheet Vinyl Floor Covering with Reinforced PVC Intermediate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods do not effectively convert sheet vinyl into smaller elements that can be combined to create a floor covering, limiting its adaptability and functionality.
Innovation Solution
A method involving the use of a PVC intermediate with a reinforcing sheet and a laminated sheet vinyl, comprising a reinforced PVC layer, a decorative layer, and a wear layer, to create a floor covering that can be easily divided into individual elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If sheet vinyl is used as a continuous material, then production efficiency is high, but it cannot be converted into smaller elements for combined floor coverings
Solution Approach 1:
The patent applies segmentation by dividing the continuous sheet vinyl into smaller modular elements (tiles, planks, or other geometric shapes) that can be combined to form floor coverings. This is achieved through a cutting device that segments the high-speed produced sheet vinyl into usable smaller units, resolving the contradiction between maintaining high production efficiency and enabling convertibility to smaller elements.
2Adaptability or versatility
If sheet vinyl is converted into smaller elements after production, then adaptability improves, but production time increases
Solution Approach 1:
The patent implements preliminary action by integrating the segmentation cutting process immediately after sheet vinyl production while the material is still in a suitable state. The cutting device is positioned to segment the sheet vinyl right after it leaves the production line, performing the conversion to smaller elements as a preliminary step before installation, thereby minimizing additional production time while maximizing adaptability.
3Speed
If traditional floor panel manufacturing methods are used, then structural integrity is maintained, but production speed is limited
Solution Approach 1:
The patent applies parameter changes by utilizing the physical state and properties of freshly produced sheet vinyl immediately after manufacturing. The segmentation is performed while the material parameters (temperature, flexibility, molecular structure) are still optimal, allowing high-speed cutting while maintaining structural integrity. This resolves the contradiction by changing the temporal parameter of when segmentation occurs rather than altering the material composition.
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
This method allows for the efficient conversion of sheet vinyl into floor covering elements, enhancing adaptability and reducing production costs by utilizing high-speed production processes for raw material sourcing.
Implementation Method 1
Passing said heated PVC granulate by the transporting device along a continuous pressing device for consolidating the PVC granulate thereby providing the PVC intermediate
Implementation Method 2
Passing said PVC granulate by the transporting device along a heating means for heating said PVC granulate on said first reinforcing sheet
Implementation Method 3
Passing said heated PVC granulate by the transporting device along a continuous pressing device for consolidating the PVC granulate
Implementation Method 4
Adhering said sheet vinyl to the PVC intermediate by lamination the lower side of the sheet vinyl to the upper side of the PVC intermediate
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method to provide a floor covering, comprising the steps of: Providing a sheet vinyl; Providing a PVC intermediate comprising at least a first layer of PVC material and at least a first reinforcing sheet, the first layer of PVC material providing the upper side of the PVC intermediate; Adhering said sheet vinyl to the PVC intermediate by lamination the lower side of the sheet vinyl to the upper side of the PVC intermediate.