Coextruded WPC Composite Floor with PVC Equilibrium Layers
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Solution Overview
Problem
Existing PVC and WPC floors are heavy, prone to delamination, warpage, and have short service life due to insecure bonding and lack of high-temperature resistance.
Innovation Solution
A composite floor is developed using a coextrusion process with a PVC equilibrium layer, a WPC foaming layer, and a second PVC equilibrium layer, eliminating the need for glue and enhancing stability and durability through compression moulding, which includes optional layers like a mute layer, printing film, and wear-resistant layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If glue is used to bond layers of WPC floor, then the floor can be assembled, but the bonding becomes insecure leading to delamination and complex manufacturing process
Solution Approach 1:
The patent merges the bonding function into the extrusion process itself by using a barrier layer with adhesive properties that is co-extruded with the other layers. This eliminates the separate gluing step while maintaining secure bonding between layers, resolving the contradiction between manufacturing simplicity and bonding security.
Solution Approach 2:
The barrier layer acts as an intermediary between the WPC layers, providing both the bonding function and the adhesive property in a single integrated component. This mediator approach allows layers to bond securely without requiring external adhesives or complex assembly processes.
2Ease of manufacture
If glue is used to bond layers, then the floor can be assembled, but labor cost increases
Solution Approach 1:
The bonding function is merged into the extrusion process through the barrier layer, eliminating the need for separate gluing operations and reducing labor requirements. This integrated approach maintains assembly capability while significantly reducing labor costs.
3Strength
If ordinary PVC floor with dense layers is used, then the floor has good structural integrity, but the floor becomes heavy making use inconvenient
Solution Approach 1:
The patent applies local quality by using a foamed core layer only in the region where weight reduction is needed, while maintaining dense skin layers at the surfaces where structural integrity and strength are required. This localized approach allows the floor to be lightweight yet structurally sound.
Solution Approach 2:
The floor uses a composite structure combining foamed material (for weight reduction) with dense PVC skin layers (for strength and integrity). This composite approach allows simultaneous achievement of lightweight properties and structural strength.
4Weight of moving object
If WPC floor with foaming material layer is used, then the floor becomes lightweight, but it is not high-temperature resistant and begins to warp above 50°C
Solution Approach 1:
The dense skin layers are positioned at the surfaces where temperature resistance is critical, while the foamed core provides weight reduction in the interior. This local quality distribution allows the floor to be lightweight yet resistant to high temperatures and warping.
Solution Approach 2:
The composite structure combines foamed material (lightweight) with dense PVC layers (heat resistant), creating a floor that simultaneously achieves weight reduction and high-temperature resistance, preventing warping above 50°C.
5Duration of action of stationary object
If PVC equilibrium layers are made with high PVC content, then the floor has good durability, but the manufacturing cost increases
Solution Approach 1:
High PVC content is concentrated in the skin layers where durability and service life are most critical, while the core layer uses less expensive foamed material. This local quality approach maintains long service life in the wear-prone surface regions while reducing overall PVC consumption and manufacturing cost.
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 composite floor is lightweight, resistant to high temperatures, minimizes delamination and warpage, and has a longer service life with improved manufacturing efficiency and environmental friendliness.
Implementation Method 1
a coextrusion layer compression moulded by using a coextrusion process. The coextrusion layer includes a first polyvinyl chloride (PVC) equilibrium layer, a wood/plastic composite (WPC) foaming layer, and a second PVC equilibrium layer sequentially arranged from top to bottom
Implementation Method 2
a coextrusion layer compression moulded by using a coextrusion process
Implementation Method 3
a wood/plastic composite (WPC) foaming layer
Data Source
AI summary
The present invention provides a composite floor and a manufacturing method thereof. The composite floor comprises a coextrusion layer compression moulded by a coextrusion process. The coextrusion layer comprises a first PVC (polyvinyl chloride) equilibrium layer, a WPC (Wood/Plastic Composite) foaming layer, and a second PVC equilibrium layer sequentially arranged from top to bottom. In the composite floor of this invention, the WPC foaming layer is the main material layer, and thus the whole weight of the floor is reduced. The first PVC equilibrium layer and the second PVC equilibrium layer are arranged respectively at two sides of the WPC foaming layer so that the composite floor is more stable in performance. It is more friendly to environment and simple in manufacturing procedure to adopt the coextrusion process for compression moulding because of avoiding bonding using glue.