Two-Layer Thermoplastic Floor Panel for Dimensional Stability
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Solution Overview
Problem
Existing floor panels made of flexible PVC substrates suffer from telegraphing effects, dimensional instability, bending, and limited structural strength, making them prone to deformation and scratching, while rigid extruded substrates face similar issues with deformation and limited dimensional stability.
Innovation Solution
A floor panel design comprising a substrate with two layers of thermoplastic materials, where the first layer has a lower saturation value than the second layer, and optionally reinforced with glass-fibre mats, and a foamed layer providing enhanced stability and strength, combined with a decorative top layer and coupling mechanisms for secure installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a substrate of flexible PVC is used, then waterproofing and walking comfort are improved, but dimensional stability and resistance to deformation worsen
Solution Approach 1:
The patent applies composite materials by combining flexible PVC substrate with a glass-fibre mat reinforcing layer impregnated with PVC. This composite structure maintains the waterproofing properties of PVC while the glass-fibre layer provides dimensional stability and resistance to deformation, resolving the contradiction between flexibility and structural integrity.
2Ease of operation
If a substrate of flexible PVC is used, then walking comfort is improved, but resistance to scratching and staining worsens
Solution Approach 1:
The patent combines the soft flexible PVC substrate that provides walking comfort with a durable glass-fibre mat layer and UV-cured varnish surface coat that resist scratching and staining. This multi-layer composite structure addresses both comfort and durability requirements simultaneously.
3Reliability
If a glass-fibre mat impregnated with flexible PVC is used as reinforcing layer, then interaction between substrate and reinforcing layer is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the reinforcing layer and the finishing layer into a single integrated glass-fibre mat structure that is impregnated with PVC. This consolidation improves layer interaction and structural integrity while simplifying the manufacturing process by reducing the number of separate manufacturing steps.
Data Source
AI summary
A floor panel including at least one substrate and a top layer, where the substrate includes at least one first layer of a first thermoplastic material and a second layer of a second thermoplastic material. The second layer is adjacent to a first side of the first layer and the second layer provides the floor panel with its underside. The first layer is characterized by a first colour with saturation value S 1 in the HSL colour space and the second layer is characterized by a second colour with saturation value S2 in the HSL colour space, where S 1 is less than S2.