Light-Foamed SPC Core Layer for Low Density and Heat Warpage
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing SPC floors face issues of high density and poor heating warpage, leading to increased transportation costs and mechanical instability.
Innovation Solution
A core flooring layer composition for light-foamed SPC floors comprising specific ratios of calcium carbonate, polyvinyl chloride, foaming regulators, stabilizers, plasticizers, and foaming agents, along with a manufacturing process using a counter-rotating cone twin-screw extruder, reduces density and improves mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional SPC floor composition is used, then mechanical strength is maintained, but density is high (1.9-2.0 g/cm³) leading to increased transportation costs
Solution Approach 1:
The patent introduces a foamed core flooring layer with controlled porosity (density 1.65-1.71 g/cm³) by incorporating foaming agents (ADC and NC) and foaming regulators. The foam structure creates voids within the material, reducing density while maintaining mechanical integrity through the cellular framework, thus resolving the contradiction between weight reduction and strength preservation.
Solution Approach 2:
The patent uses a composite formulation combining calcium carbonate (65-75 wt%), polyvinyl chloride resin (18-25 wt%), and various additives including foaming agents, stabilizers, and lubricants. This composite material approach allows optimization of both density and mechanical properties by carefully selecting and balancing the components, achieving light weight without sacrificing strength.
2Weight of moving object
If density is reduced to lower transportation costs, then weight decreases, but heating warpage performance deteriorates (0.56-0.73 mm warpage)
Solution Approach 1:
The patent optimizes multiple parameters simultaneously: calcium carbonate particle size distribution (700-800 mesh and 300-500 mesh ratios), foaming agent quantities (ADC 0.1-0.40 wt%, NC 0.5-1.0 wt%), and foaming regulator content (2.2-3.0 wt%). These parameter adjustments control the foam cell structure and distribution, reducing thermal expansion anisotropy and minimizing heating warpage to below 0.5 mm while maintaining low density.
Solution Approach 2:
The patent creates non-uniform calcium carbonate particle distribution within the foam structure, using a bimodal size distribution (coarse 700-800 mesh and fine 300-500 mesh particles). This local variation in particle size and foam cell density throughout the material provides localized reinforcement that compensates for thermal warping while maintaining overall light weight.
3Weight of moving object
If foaming agents are added to reduce density, then weight decreases, but manufacturing complexity increases due to additional additives and process control
Solution Approach 1:
The patent combines multiple functions into integrated components: the foaming agents (ADC and NC) serve both density reduction and structural formation purposes, while the foaming regulator simultaneously controls foaming rate and final cell structure. The calcium carbonate particle size distribution also serves dual purposes of mechanical reinforcement and foam stability. This merging of functions reduces the need for separate process steps and simplifies manufacturing despite the multiple additives.
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 achieves a significant reduction in density and enhances mechanical properties such as static bending strength, bending elastic modulus, and peel strength while minimizing heating warpage.
Implementation Method 1
0.10 ̃0.40 wt % of an ADC foaming agent, and 0.5 ̃1.0 wt % of an NC foaming agent
Implementation Method 2
azodicarbonamide in a content of 99.4 ̃99.8 wt %, urea in a content of 0.1 ̃0.3 wt %
Implementation Method 3
2.2 ̃3.0 wt % of a foaming regulator; preferably, the content of the foaming regulator is 2.4 ̃3.0 wt %
Implementation Method 4
2.5 ̃3.3 wt % of a stabilizer; preferably, the stabilizer is a calcium zinc stabilizer, such as one or a combination of calcium stearate and zinc stearate
Implementation Method 5
0.10 ̃0.15 wt % of an external lubricant; preferably, the external lubricant is selected from one or more of PE wax or oxidized polyethylene wax
Implementation Method 6
0.10 ̃0.20 wt % of a plasticizer; preferably, the plasticizer is oxidized polyethylene wax
Data Source
AI summary
Provided in the present disclosure are a core flooring layer of a light-foamed SPC floor and a light-foamed SPC floor. Based on the total weight of the core flooring, the core flooring of the present disclosure contains 65.0˜75.0 wt % of calcium carbonate, 18.0˜25.0 wt % of polyvinyl chloride resin, 2.2˜3.0 wt % of a foaming regulator, 2.5˜3.3 wt % of a stabilizer, 0.10˜0.20 wt % of a plasticizer, 0.10˜0.15 wt % of an external lubricant, 0.1˜0.40 wt % of an ADC foaming agent, and 0.5˜1.0 wt % of an NC foaming agent. The present disclosure can greatly reduce the density of a SPC floor while improving the static bending strength, flexural elastic modulus and peeling strength, and reducing heating warpage.