Two-Layer Thermoplastic Floor Panels for Dimensional Stability
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Solution Overview
Problem
Existing floor panels made of soft PVC substrates suffer from telegraphing effects, dimensional instability, bending, and limited structural integrity, leading to installation challenges and susceptibility to scratching and staining.
Innovation Solution
A floor panel design comprising a substrate with two layers of thermoplastic materials, each with distinct luminance values in the HSL color space, and optionally reinforced with glass-fibre mats, to enhance dimensional stability and structural integrity, while minimizing color differences at edges for improved aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a soft PVC substrate is used, then walking comfort is improved and tapping noise is reduced, but dimensional stability deteriorates and telegraphing effects occur
Solution Approach 1:
The patent applies composite materials by combining soft PVC substrate with a reinforcing layer consisting of glass-fibre mat impregnated with flexible PVC. This composite structure maintains the softness and walking comfort of the PVC while the glass-fibre reinforcement provides dimensional stability and prevents telegraphing effects. The reinforcing layer acts as a structural backbone that compensates for the inherent flexibility of the soft PVC substrate.
2Object-generated harmful factors
If a soft PVC substrate is used, then tapping noise is reduced, but structural integrity deteriorates and bending occurs
Solution Approach 1:
The patent uses a composite structure where the soft PVC substrate is combined with a reinforcing layer of glass-fibre mat impregnated with flexible PVC. The glass-fibre reinforcement provides the necessary structural integrity and resistance to bending, while the soft PVC layers maintain the noise-dampening properties. This composite approach allows the floor panel to remain quiet underfoot while gaining sufficient strength.
Solution Approach 2:
The patent applies local quality by concentrating the reinforcement in a specific layer between the soft PVC substrate and the wearing layer. The glass-fibre mat impregnated with flexible PVC is positioned strategically to provide structural support where needed, while allowing the outer soft PVC layers to maintain their noise-reducing characteristics. This localized reinforcement optimizes both noise reduction and structural integrity.
3Stability of the object's composition
If a reinforcing layer of glass-fibre mat impregnated with flexible PVC is added, then dimensional stability is improved, but device complexity increases
Solution Approach 1:
The patent integrates the reinforcing function into a composite layer that combines glass-fibre mat with flexible PVC impregnation. This approach adds dimensional stability without requiring separate reinforcement components or complex assembly steps. The impregnated structure allows the reinforcing layer to be manufactured as an integrated unit, reducing overall device complexity despite the enhanced functionality.
4Strength
If the substrate is made rigid to prevent bending, then structural integrity is improved, but ease of installation deteriorates
Solution Approach 1:
The patent employs a composite structure with a soft PVC substrate reinforced by a glass-fibre mat layer impregnated with flexible PVC. This combination provides sufficient structural integrity to prevent bending during installation while maintaining the flexibility and ease of handling characteristic of soft PVC. The reinforcing layer is designed to provide just enough stiffness to prevent deformation without making the panel rigid and difficult to install.
Data Source
AI summary
A floor panel including a top layer and a substrate, where the substrate at least one first layer of a first thermoplastic material and a second layer of a second thermoplastic material, where the second layer is adjacent to a first side of the first layer. The first layer is characterized by a first colour with luminance value L1 in the HSL colour space and the second layer is characterized by a second colour with luminance value L2 in the HSL colour space, where L1 is different from L2.