Synchronous Co-Extruded SPC Flooring for Accurate Pattern Registration
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Solution Overview
Problem
Conventional floorboard manufacturing processes face issues such as high costs, complex procedures, energy consumption, glue overflow, warpage, and inaccurate pattern alignment due to slow response of base material conveying speed and thin printed film shifting during calendering.
Innovation Solution
An online synchronously pattern-aligned coextruded SPC floorboard with a three-layer base material structure and a process using coextrusion and calendering to achieve stable lamination, accurate pattern alignment, and UV resistance, employing a five-roller calender and PLC control for real-time adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hot-press laminating process is used to achieve pattern alignment, then pattern alignment can be achieved, but the process becomes complex, expensive, and energy-intensive with glue overflow and long press-bonding time
Solution Approach 1:
The patent extracts and eliminates the glue lamination step from the conventional hot-press process. Instead of using glue to bond the decorative paper to the base board, the invention uses a calendering process where a patterned roller directly imprints the design onto the base board material, achieving pattern alignment without adhesive application and subsequent bonding operations.
Solution Approach 2:
The patent replaces the thermal-mechanical glue lamination system with a purely mechanical calendering system. The patterned roller mechanically transfers the design pattern directly onto the base board through applying pressure, eliminating the need for thermal pressing and adhesive bonding mechanisms.
2Manufacturing precision
If manual plate alignment is used to achieve pattern alignment, then pattern alignment can be achieved, but the process becomes time-consuming and laborious with difficult-to-guarantee results
Solution Approach 1:
The patent implements self-aligning mechanism through the calendering process. The patterned roller automatically adjusts and maintains alignment with the base board as it passes through the calender, eliminating the need for manual alignment operations. The mechanical contact and pressure application naturally maintain pattern registration throughout the rolling process.
Solution Approach 2:
The patent replaces manual alignment operations with an automated mechanical calendering system that continuously maintains pattern alignment. The patterned roller, being in direct mechanical contact with the base board, automatically ensures consistent pattern registration without human intervention throughout the production process.
3Productivity
If calendering process is used to achieve pattern alignment, then automation and efficiency are improved, but the base material conveying speed responds slowly due to high inertia and cannot be maintained for long periods
Solution Approach 1:
The patent implements dynamic speed adjustment capability in the calendering system. The conveying rollers are equipped with independent speed control mechanisms that can rapidly adjust their rotation speed to match changes in base board speed. This dynamic response capability allows the system to maintain synchronization between the patterned roller and base board even during speed variations, overcoming the inertia limitation through active, real-time speed modulation.
4Manufacturing precision
If printed film is used in calendering process, then pattern alignment can be achieved, but the thin printed film easily shifts or develops folds during conveying affecting the fitting result
Solution Approach 1:
The patent extracts and eliminates the thin printed film from the process. Instead of using a separate printed decorative layer that is prone to shifting and folding, the invention directly patterns the base board material itself through the calendering process. The pattern is imprinted onto the base board as it passes through the patterned roller, eliminating the intermediate thin film layer that causes stability problems.
Solution Approach 2:
The patent performs the patterning action preliminarily on the base board material itself rather than on a separate decorative film. By directly imprinting the pattern onto the base board through the patterned roller during calendering, the system eliminates subsequent issues with film shifting and folding that would occur if a separate printed layer were used.
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 process ensures stable pattern alignment, prevents warpage and layer splitting, and produces a durable, aesthetically pleasing floorboard with UV resistance and soundproofing properties.
Implementation Method 1
a five-roller calender to press and bond the decorative layer and the wear-resistant layer onto the base material layer
Implementation Method 2
a process using coextrusion and calendering to achieve stable lamination
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.