Ventilating Synthetic Floor Covering with Narrow Channel Studs
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Solution Overview
Problem
Existing ventilating synthetic floor-coverings with button-shaped supports lose their ventilating effect over time due to the texture becoming visible under heavy traffic, compromising moisture vapor passage and adhesive bonding.
Innovation Solution
A ventilating synthetic floor-covering with a support layer featuring narrow ventilation channels between studs, where the channels' width is less than the principal dimension of the studs, allowing for improved support, bonding, and moisture vapor passage, achieved through embossing or printing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If button-shaped supports are used in the support layer, then ventilation is provided during installation, but the texture becomes visible under heavy traffic and ventilating effect is lost
Solution Approach 1:
The invention changes the geometric parameters of the support layer from button-shaped supports with wide pathways to studs with narrow ventilation channels. The channel width is specifically controlled to be less than the principal dimension of the studs, creating a configuration that maintains ventilation functionality while resisting texturing under traffic loads.
2Object-affected harmful factors
If wide pathways are formed between button-shaped supports, then moisture vapor can escape, but the support area is reduced and bonding strength is compromised
Solution Approach 1:
The invention optimizes the dimensional parameters by forming narrow ventilation channels whose width is less than the principal dimension of the studs. This parameter change increases the stud surface area for bonding while maintaining adequate moisture vapor passage through the narrow channels.
3Strength
If adhesive is used to secure the floor covering, then bonding strength is improved, but removal and recycling become difficult and subfloor damage occurs
Solution Approach 1:
The stud-shaped supports with their textured surface provide self-bonding characteristics through mechanical interlocking and increased surface area contact. This self-service bonding mechanism eliminates or reduces the need for separate adhesive applications, allowing for easy removal and recycling without subfloor damage.
4Strength
If adhesive or floor screed is used for installation, then bonding is achieved, but drying or setting time is required before the floor can be used
Solution Approach 1:
The stud-shaped support layer provides immediate mechanical bonding through its textured surface that engages with the subfloor. This self-bonding mechanism eliminates the need for adhesive drying or floor screed setting time, allowing the floor to be used immediately after installation.
Data Source
AI summary
The invention provides a ventilating synthetic floor-covering comprising a ventilating support layer and one or more synthetic layers wherein the ventilating support layer comprises a plurality of studs between which narrow ventilation channels are formed even when the floor-covering is compressed in normal use wherein the narrow ventilation channels have a width which is less than a principal dimension of the studs; a ventilating support layer; a production line for use in the preparation of a ventilating support layer wherein the ventilating support layer comprises a support layer and a plurality of studs wherein the production line comprises an embossing roller for embossing the plurality of studs on the support layer or a printing roller for printing the plurality of studs on the support layer wherein narrow ventilation channels are formed between the plurality of studs and wherein the narrow ventilation channels have a width which is less than a principal dimension of the studs; and a method of preparing a synthetic floor-covering according to the invention which method comprises a step of providing a synthetic floor-covering comprising an upper layer and a support layer; and one of the following steps:(a) embossing the support layer to form a plurality of studs between which one or more narrow ventilation channels are formed;(b) embossing the upper layer before embossing the support layer to form a plurality of studs between which one or more narrow ventilation channels are formed;(c) embossing the support layer to form a plurality of studs between which one or more narrow ventilation channels are formed before embossing the upper layer;(d) embossing the support layer and the upper layer at the same time wherein the support layer is embossed to form a plurality of studs between which one or more narrow ventilation channels are formed; or(e) applying one or more studs by printing to form a plurality of studs between which one or more narrow ventilation channels are formed;wherein the narrow ventilation channels have a width which is less than a principal dimension of the studs.