Co-Extruded SPC Foam Flooring With an Internal Foam Layer for Lower Weight
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional SPC flooring has a high density, leading to increased weight per unit area and transportation costs.
Innovation Solution
A co-extrusion SPC foam flooring with a stone-plastic base material structure comprising a foaming layer between two stable layers, reducing density to 1.4 to 1.6 g/cm3, and incorporating additives like calcium carbonate and PVC resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional SPC flooring with high density (1900-2000 kg/m3) is used, then strength and stability are improved, but weight and transportation costs increase
Solution Approach 1:
The patent introduces a foaming layer with porous structure between the two stable layers. This foaming layer contains air pockets that reduce the overall density of the flooring from 1900-2000 kg/m3 to a lower value, thereby reducing weight while maintaining structural integrity through the sandwich configuration.
Solution Approach 2:
The patent creates a composite structure consisting of three distinct layers: two stable SPC layers and one foaming layer. This composite material approach combines the density and strength benefits of traditional SPC with the weight reduction benefits of foam, achieving a balance between strength and weight.
2Stability of the object's composition
If traditional SPC flooring with high density is used, then structural stability is improved, but transportation costs increase
Solution Approach 1:
The foaming layer with porous structure reduces the overall weight of the flooring by introducing air pockets, which directly decreases transportation costs while the sandwich structure maintains structural stability through the protective stable layers.
Solution Approach 2:
The patent changes the density parameter of the flooring by introducing a foaming layer, reducing it from the traditional high density range. This parameter change results in weight reduction and lower transportation costs while maintaining adequate structural stability.
3Weight of moving object
If a foaming layer is introduced to reduce density, then weight is reduced, but structural stability may worsen
Solution Approach 1:
The patent segments the flooring into three functional layers: two stable layers that provide structural support and stability, and a middle foaming layer that provides weight reduction. This segmentation allows each layer to perform its specific function, with the stable layers compensating for the reduced stability from the foaming layer.
Solution Approach 2:
The composite sandwich structure combines materials with different properties: dense stable SPC layers for structural stability and a lightweight foaming layer for weight reduction. The combination creates a synergistic effect where the overall structure achieves both weight reduction and maintained stability.
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 foaming layer reduces overall density while maintaining surface strength and enhancing sound-absorbing performance, with improved dimensional stability.
Implementation Method 1
the foaming layer is a chemical foaming layer or a physical foaming layer
Data Source
AI summary
A foam flooring includes a stone-plastic base material structure, which sequentially comprises, from top to bottom, a first stable layer, a foaming layer and a second stable layer. The first stable layer and the second stable layer are both sheets with a PVC resin and filler powder as main components, with 25-40 parts by mass of the PVC resin and 55-75 parts by mass of the filler powder; and the density of the SPC foam flooring is 1.4-1.6 g/cm3. The foaming layer is arranged between the two stable layers, such that the overall density of the flooring is significantly reduced and reaches 1.4-1.6 g/m3; since the foaming layer is arranged inside, the surface strength of the overall flooring is not influenced.