Stone-Plastic Flooring Layered Structure for Density and Acoustic Control
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Solution Overview
Problem
Existing stone-plastic hot pressing flooring has high density, poor foot feeling, and high mute value, which are significant drawbacks.
Innovation Solution
The solution involves a stone-plastic hot pressing flooring structure with a middle material layer and a bottom material layer, both composed of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone powder, symmetrically arranged relative to a stone-plastic substrate layer, along with wear-resistant layers and a color film, to reduce density and improve foot feeling and sound absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional stone-plastic hot pressing flooring is used with high stone powder content, then wear resistance and hardness are improved, but density increases and foot feeling deteriorates
Solution Approach 1:
The flooring is divided into multiple functional layers: wear-resistant layer (0.5-1.5mm with high stone powder content for durability), pattern layer (0.2-0.5mm for aesthetics), and cushioning layer (2-5mm with low stone powder content for comfort). This segmentation allows each layer to optimize its properties independently, resolving the contradiction between hardness and foot feeling.
Solution Approach 2:
Different regions of the flooring have different material compositions tailored to their specific functions. The wear-resistant layer uses 80-90% stone powder for maximum durability, while the cushioning layer uses 30-50% stone powder for comfort. This local quality differentiation resolves the contradiction by applying high density only where needed for wear resistance.
2Stability of the object's composition
If high stone powder content is used in the base layer, then structural stability is improved, but mute value increases and sound absorption deteriorates
Solution Approach 1:
The base layer is segmented into a structural sub-layer (1-3mm with 70-85% stone powder for stability) and a cushioning sub-layer (2-5mm with 30-50% stone powder for sound absorption). This segmentation allows the structural layer to provide stability while the cushioning layer reduces mute value.
Solution Approach 2:
The stone powder content varies by layer: high concentration (70-85%) in the structural layer for stability, and low concentration (30-50%) in the cushioning layer for sound absorption. This local quality approach resolves the contradiction between structural stability and mute value.
3Duration of action of stationary object
If the wear-resistant layer thickness is increased, then service life is improved, but manufacturing cost and processing complexity increase
Solution Approach 1:
The flooring uses a segmented multi-layer structure where the wear-resistant layer (0.5-1.5mm) is optimized for durability while thinner pattern and cushioning layers reduce overall processing complexity. The segmentation allows each layer to be manufactured and bonded independently, simplifying the overall process.
Solution Approach 2:
The wear-resistant layer thickness is optimized to 0.5-1.5mm, which provides sufficient service life (10-20 years) while avoiding excessive thickness that would complicate manufacturing. This parameter optimization balances service life with processing complexity.
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 configuration reduces the density and hardness of the flooring, enhancing foot feeling and sound absorption while maintaining stability, resulting in improved product performance.
Implementation Method 1
both the middle material layer and the bottom material layer are mainly composed of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone powder
Implementation Method 2
symmetrically arranging the middle material layer and the bottom material layer relative to the stone-plastic substrate layer
Data Source
AI summary
The present invention provides stone-plastic hot pressing flooring including a stone-plastic base material part which includes a middle material layer, a stone-plastic substrate layer, and a bottom material layer sequentially arranged side by side; —a color film layer, located at one side of an upper surface of the stone-plastic base material part; —a first wear-resistant layer, located at one side of an upper surface of the color film layer; and —a second wear-resistant layer, located at one side of a lower surface of the stone-plastic base material part; and wherein the middle material layer and the bottom material layer are mainly composed of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone powder.