Synchronous Co-Extruded SPC Flooring for Precise Pattern Alignment
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Solution Overview
Problem
Conventional floorboard manufacturing processes face issues such as high costs, complex procedures, energy consumption, glue overflow, layer splitting, warpage, and inaccurate pattern alignment due to slow speed adjustments and thin film shifting during calendering.
Innovation Solution
An online synchronously pattern-aligned coextruded SPC floorboard with a three-layer base material structure and a process that includes coextrusion, calendering, and a five-roller system for precise pattern alignment, using a PLC control system for real-time adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hot-press laminating process is used for pattern alignment, then pattern alignment can be achieved, but the process becomes complex, expensive, and energy-consuming with glue overflow and layer splitting issues
Solution Approach 1:
The patent extracts and eliminates the glue application step from the conventional hot-press laminating process. By using a calendering process where the decorative paper is pressed directly onto the base board without glue, the complexity of the process is reduced while maintaining pattern alignment accuracy. This removes the source of glue overflow and layer splitting problems.
Solution Approach 2:
The patent replaces the mechanical hot-press laminating system with a calendering system. Instead of using heat and pressure to bond layers with glue, the invention uses a calender with embossed rollers to mechanically transfer the pattern directly, achieving pattern alignment through mechanical means rather than thermal-chemical bonding.
2Manufacturing precision
If manual plate alignment is used, then pattern alignment can be performed, but it becomes time-consuming and laborious with difficult-to-guarantee results
Solution Approach 1:
The patent implements self-service pattern alignment through the calendering process. The embossed rollers automatically transfer the pattern onto the base board as they pass through the calender, eliminating the need for manual alignment operations. The pattern alignment occurs automatically during the calendering process itself, saving time and improving consistency.
Solution Approach 2:
The patent maintains continuous pattern alignment throughout the calendering process. Instead of separate alignment steps, the pattern transfer occurs continuously as the base board passes through the calender rollers, ensuring consistent alignment without interruption or manual intervention.
3Productivity
If calendering pattern alignment is used, then automation and efficiency increase, but base board and printed film may not be conveyed synchronously causing offset
Solution Approach 1:
The patent incorporates feedback mechanisms to monitor and adjust the conveyance of the base board and decorative paper during calendering. By detecting deviations in pattern alignment and automatically adjusting the conveyance speeds or positions, the system maintains synchronous movement of all layers, preventing offset while preserving high productivity.
4Manufacturing precision
If base board conveying speed is adjusted during calendering, then pattern alignment can be corrected, but the base board responds slowly due to high inertia and cannot maintain adjustment
Solution Approach 1:
The patent implements dynamic adjustment of the calendering process parameters to accommodate the base board's inertia. By using variable speed control and adaptive positioning systems that account for the base board's mass and response characteristics, the system achieves quick and maintainable adjustments in conveying speed, overcoming the inertia limitation.
5Manufacturing precision
If printed film is adjusted during conveying, then pattern alignment can be improved, but the thin film easily shifts or develops folds affecting fitting result
Solution Approach 1:
The patent provides beforehand cushioning for the thin decorative paper by using supportive calender rollers and controlled tension during the calendering process. The rollers are designed to support the thin film without causing folds or shifts, and the process parameters are controlled to maintain film stability throughout the adjustment period, preventing defects before they occur.
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 stable lamination, accurate pattern alignment, and enhanced dimensional stability, preventing layer splitting and warpage, with improved wear and UV resistance, and a distinct 3D pattern.
Implementation Method 1
a base material layer consisting of a three-layer structure of an elastic layer, a strength layer and a stability layer
Implementation Method 2
a decorative layer and a wear-resistant layer are pre-fitted to the base material layer
Implementation Method 3
an embossed pattern on a surface of the pattern alignment roller is applied to the wear-resistant layer in an online synchronous fashion
Data Source
AI summary
On-line synchronous registering co-extrusion SPC floor includes a base material layer, a decorative layer, and a wear-resistant layer. The decorative layer is arranged on the base material layer and provides patterns and designs. The wear-resistant layer is arranged on the decorative layer, is a transparent layer or a semi-transparent layer, and is provided with a concave-convex surface. The patterns or designs correspond to the concave-convex surface; the base material layer is composed of an elastic layer, a strength layer, and a stable layer, and shading is pressed on the bottom layer of the stable layer. Two co-extrusion lines are used for simultaneous extrusion to achieve an ABA three-layer effect of an SPC base material layer. A calender matches a synchronous registering system, and the patterns of the decorative layer are formed in a rolling manner.