Halogen-Free Decorative Surface Covering Composition
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Solution Overview
Problem
Conventional PVC extruders are unable to process rubber-based decorative surface coverings effectively due to high viscosity and vulcanization temperature requirements, leading to issues like agglomeration and the need for specialized equipment, while existing alternatives lack tear resistance, stain resistance, and flame retardancy, and are costly.
Innovation Solution
A halogen-free decorative surface covering composition comprising a blend of styrene butadiene styrene block copolymer, nitrile butadiene rubber, high styrene content styrene butadiene copolymer, fillers, and a vulcanization system, processed using conventional PVC equipment with a polyurethane-based top coating, allowing for improved processing and enhanced properties like scratch resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rubber-based compositions are processed using conventional PVC extruders, then processing capability is improved, but the composition cannot be extruded and sticks on the steel belts
Solution Approach 1:
The patent modifies the chemical composition parameters by incorporating specific polymer blends (SBS block copolymer, HSR, SBR rubber) and controlling their ratios, along with using specific fillers and curing agents, to enable the composition to be processed on conventional PVC extruders without sticking to steel belts
Solution Approach 2:
The patent creates a composite material system combining thermoplastic polymers (SBS, HSR), rubber (SBR), fillers, and curing agents in specific proportions to achieve both processability on PVC equipment and desired mechanical properties, resolving the contradiction between processing ease and extrusion stability
2Reliability
If high styrene resin and SBR rubber are used in high amounts for conductive floor covering, then electrical conductivity is improved, but rubber equipment becomes necessary
Solution Approach 1:
The patent adjusts the composition parameters by incorporating carbon black as a filler alongside the polymer blend, achieving electrical conductivity while maintaining compatibility with conventional PVC extrusion equipment, thus avoiding the need for specialized rubber equipment
3Strength
If conventional PVC compositions are used, then abrasion resistance and dimensional stability are improved, but environmental safety deteriorates due to VOC release and toxicity
Solution Approach 1:
The patent replaces harmful PVC components with environmentally safer alternatives (SBS, HSR, SBR rubber blends) while maintaining or improving mechanical properties like abrasion resistance, effectively converting the environmental harm into a benefit by eliminating VOCs and toxic plasticizers
Solution Approach 2:
The patent develops a composite material system using rubber-polymer blends with specific fillers and curing agents that achieves the required mechanical performance without the environmental drawbacks of conventional PVC, balancing strength and environmental safety
4Ease of manufacture
If standard rubber floor covering compositions are used, then processing simplicity is improved, but tear resistance and stain resistance deteriorate
Solution Approach 1:
The patent creates a composite formulation combining thermoplastic polymers (SBS, HSR) with rubber (SBR) and specific fillers in controlled ratios, achieving both processing simplicity and enhanced mechanical properties including improved tear and stain resistance compared to standard rubber compositions
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 enables the use of conventional PVC extruders for processing, achieving good scratch resistance and processing ability, while maintaining cost-effectiveness and environmental safety by avoiding halogen-containing polymers.
Implementation Method 1
a vulcanisation system; The present invention discloses a decorative surface covering obtainable by a vulcanisable composition
Implementation Method 2
conventional PVC extrusion equipment; processed using conventional PVC equipment
Data Source
AI summary
The present invention relates to a decorative surface covering obtainable by a vulcanisable composition, said composition comprising a first polymer component consisting of styrene butadiene styrene block copolymer (SBS); a second polymer component selected from the group consisting of a random or partially random copolymer of butadiene and styrene (SBR), and nitrile butadiene rubber (NBR); a third polymer component consisting of a high styrene content styrene butadiene copolymer (HSR), a filler, a vulcanisation system and additives selected from the group consisting of processing aids, stabilizers, pigments and compatibilizers.