Vinyl Fabric Laminated Flooring for Impact Sound and Outdoor Stability
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Solution Overview
Problem
Existing modular laminated flooring elements lack optimal elastic behavior and are not suitable for outdoor use, as they do not effectively absorb impact sound or provide adequate resistance to environmental factors like UV exposure and water.
Innovation Solution
A modular laminated flooring element with a rigid base and a vinyl fabric upper layer comprising PVC outer yarns and polyester or fiberglass multifilaments, which enhances sound absorption, reduces vinyl expansion and contraction, and offers UV resistance, combined with a manufacturing method involving adhesive bonding and optional friction welding or molding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid base with a passable finishing exposed layer is used, then structural stability is improved, but impact sound absorption deteriorates
Solution Approach 1:
The patent combines a rigid base (HDF, wood composite, or PVC) with a vinyl fabric upper layer comprising yarns with polyester or fiberglass cores and PVC coatings. This composite structure maintains structural stability while the fabric construction provides impact sound absorption through its elastic yarns that cushion surface impacts.
Solution Approach 2:
The upper layer uses vinyl fabric with specific local properties: yarns containing polyester or fiberglass multifilament cores coated with PVC. This localized quality differentiation within the upper layer provides both durability and acoustic performance in specific areas where needed.
2Reliability
If a vinyl upper layer is used, then water resistance is improved, but expansion and contraction deteriorates
Solution Approach 1:
The patent employs a vinyl fabric upper layer that acts as a flexible film structure. The fabric construction with yarns containing polyester or fiberglass cores coated with PVC provides water resistance while the flexible nature of the fabric allows it to accommodate expansion and contraction through the spaces between yarns.
Solution Approach 2:
The vinyl fabric upper layer has a porous structure with spaces between yarns that can absorb expansion and contraction of the underlying rigid base. This porous construction maintains water resistance while accommodating dimensional changes.
3Duration of action of stationary object
If PVC flooring is used outdoors, then durability is improved, but UV resistance deteriorates
Solution Approach 1:
The patent uses a composite vinyl fabric upper layer with yarns containing polyester or fiberglass cores coated with PVC. The polyester or fiberglass core materials provide inherent UV resistance, while the PVC coating maintains durability and water resistance, creating a composite structure that withstands outdoor environmental factors.
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 solution provides improved impact sound absorption, noise dispersion, and enhanced durability and water resistance, making the flooring more comfortable and suitable for outdoor use.
Implementation Method 1
acoustic properties, especially due to the 'spring effect' of the yarns form which they are made, where any surface impact, like treads, are cushioned by the compression resistance of the yarns composing the fabric
Implementation Method 2
Placing an adhesive glue on one side of a rigid base (2) provided with attachment means to identical elements on its periphery; Placing on the adhesive glue a vinyl fabric sheet; Attaching the vinyl fabric to the rigid base
Implementation Method 3
a high speed milling at the edge of the vinyl fabric layer is carried out that enables friction welding the frayed edges of the vinyl fabric
Implementation Method 4
the vinyl fabric comprises yarns made of a PVC outer layer and a core of polyester or fiberglass multifilaments... With the surface layer of polymer monofilament, a great resistance to solar UV is obtained
Data Source
Figure 1~2
AI summary
The invention relates modular laminated prefabricated element 1 for flooring, comprising a rigid base 2 provided on its periphery with attachment means 5 and comprising an upper layer 3 made of vinyl fabric 4 thus providing a spring effect that dramatically improves the impact sound absorption and a large dispersion of ambient noise waves among others. It also relates to a method for obtaining said element.