Flexible Polymeric Floor Covering via Thermally Curable Resin
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Solution Overview
Problem
Current floor coverings, such as PVC and acrylate-based materials, face challenges in flexibility, cost-effectiveness, and environmental sustainability, particularly when trying to combine the benefits of non-elastic laminate and flexible floorings, and existing solutions like acrylate-based products are either too expensive or inflexible for use as floor coverings on rough surfaces.
Innovation Solution
A thermally curable composition comprising a blend of (meth)acrylate monomers and poly(meth)acrylate with added natural terpenes, thermoplastic polymers, and lightweight fillers, which can be processed to create a flexible and cost-effective polymeric material suitable for various applications, including floor coverings, without using harmful materials like PVC or phthalates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If acrylate-based materials are used for floor coverings, then flexibility and impact resistance are improved, but cost increases and environmental sustainability deteriorates due to use of harmful materials like PVC and phthalates
Solution Approach 1:
The patent replaces expensive and harmful PVC/phthalate materials with a cost-effective composition based on polyurethane, polyester, or epoxy resins combined with recycled glass fibers. This substitution achieves the desired flexibility and impact resistance while eliminating environmental harm, effectively using affordable material combinations to replace premium but problematic materials
Solution Approach 2:
The invention creates a composite material system combining polymer resins (polyurethane, polyester, or epoxy) with recycled glass fibers. This composite structure provides both the flexibility and impact resistance needed for floor coverings while using environmentally friendly, non-toxic components that replace harmful PVC and phthalates
2Ease of manufacture
If non-elastic laminate floorings are used, then manufacturing cost decreases, but flexibility and ease of installation on rough surfaces deteriorates
Solution Approach 1:
The patent modifies the material parameters by using a polymer composition with specific flexibility characteristics (polyurethane, polyester, or epoxy resins) combined with recycled glass fibers. This parameter adjustment allows the floor covering to maintain low manufacturing cost while gaining the flexibility needed to adapt to rough surfaces, bridging the gap between economical laminate and flexible vinyl
3Ease of operation
If PVC floor coverings are used, then flexibility and ease of installation are improved, but environmental sustainability deteriorates due to harmful materials
Solution Approach 1:
The patent substitutes PVC and phthalates with an affordable composition of polyurethane, polyester, or epoxy resins combined with recycled glass fibers. This replacement maintains the flexibility and ease of installation characteristics while eliminating harmful substances, achieving both operational convenience and environmental sustainability
Solution Approach 2:
The invention converts the potential harm of using flexible materials (which often rely on toxic plasticizers) into a benefit by using recycled glass fibers as a harmless alternative that provides flexibility. The glass fiber reinforcement allows the use of eco-friendly polymer resins without compromising the flexibility needed for easy installation
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 resulting polymeric material is flexible, impact-resistant, and cost-effective, with adjustable thickness and density, allowing for easy installation and reduced environmental impact, while maintaining excellent thermal, sound insulation, and flame retardation properties.
Implementation Method 1
A thermally curable composition comprising a blend of (meth)acrylate monomers and poly(meth)acrylate
Data Source
AI summary
The present invention relates to a polymeric material and to an article, such as a molded article, comprising said polymeric material, which may be used for instance in form of a sheeting as a paneling wall, a ceiling, a decorative film or a synthetic veneer and in particular as of a floor covering. Furthermore, the present invention relates to a method for producing said article, preferably said sheeting.