SPC Flooring Honeycomb Grooves for Weight and Strength Balance
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Solution Overview
Problem
Conventional flooring materials like solid wood, composite, and plastic flooring suffer from issues such as moisture absorption, insect damage, environmental impact, poor durability, and high weight, leading to increased transportation costs and structural load burdens.
Innovation Solution
A floor weight-reducing structure featuring honeycomb-shaped grooves on the bottom of SPC boards, with grooves depth ranging from ½ to ¾ of the board thickness, maintains structural integrity while reducing weight and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the board uses solid SPC material without grooves, then the board has high strength and durability, but the board weight is high increasing transportation costs
Solution Approach 1:
The board is segmented by creating honeycomb-shaped grooves that divide the solid SPC material into multiple cellular sections. This segmentation reduces the overall material volume and weight while the interconnected structure maintains structural integrity and strength through geometric distribution of loads.
Solution Approach 2:
The board incorporates a porous honeycomb structure with controlled void spaces arranged in a hexagonal pattern. This porous design significantly reduces material density and weight compared to solid material, while the cellular geometry provides structural support and maintains necessary strength characteristics.
2Weight of moving object
If the grooves are made deeper to reduce weight further, then weight reduction is improved, but the board strength and structural integrity deteriorate
Solution Approach 1:
The groove depth is optimized to a specific parameter range (1-2 cm or 1/4 to 1/2 of board thickness) that achieves the optimal balance between weight reduction and structural integrity. This parameter optimization ensures sufficient material remains to maintain strength while removing enough material to achieve significant weight reduction.
Solution Approach 2:
Instead of removing excessive material that would compromise strength, the invention applies partial action by limiting groove depth to retain sufficient structural material. The grooves penetrate partially through the board thickness rather than completely, maintaining the necessary structural core for strength while achieving weight reduction.
3Weight of moving object
If the grooves are made too close to the edges to maximize weight reduction, then weight reduction is improved, but the joining protrusion and recess strength deteriorates
Solution Approach 1:
The board exhibits local quality variation where the edge regions (1-2 cm from perimeter) maintain solid structure for joining strength, while the central region contains the honeycomb grooves for weight reduction. This localized structural differentiation ensures that critical joining areas retain full strength while the majority of the board achieves weight reduction through grooving.
Solution Approach 2:
The design preliminarily reserves solid edge regions before the grooving process is applied to the board. By pre-determining that edge areas within 1-2 cm of the perimeter remain ungrooved, the joining structures are protected from strength degradation while the grooving process proceeds in the central area to achieve weight reduction.
Data Source
AI summary
A floor weight-reducing structure includes a board, where the bottom of the board is provided with multiple grooves arranged neatly in a honeycomb pattern, and the board is made of SPC (Stone Plastic Composite) material. The floor weight-reducing structure is to provide lower manufacturing costs, lower transportation costs, and improved resistance to deformation.