Multi-Layer Foamed PVC Floorboard for Lightweight Heat Stability
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Solution Overview
Problem
Traditional PVC floorboards face challenges in balancing toughness and stability, particularly in high temperature environments, and struggle to maintain mechanical properties while reducing weight.
Innovation Solution
A multi-layer foamed PVC floorboard with a surface layer and core layer composition, incorporating specific materials and manufacturing processes to enhance toughness, stability, and reduce weight, including the use of calcium carbonate, PVC resin, calcium-zinc stabilizers, foaming agents, and a core forming technology.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional PVC floorboard uses solid structure to maintain mechanical strength, then static bending intensity is maintained, but weight increases and transportation convenience deteriorates
Solution Approach 1:
The patent applies foamed PVC materials with controlled porosity in the core layer, creating a cellular structure that reduces density and weight while maintaining adequate mechanical strength through the foam architecture. The foamed structure provides sufficient static bending intensity for floorboard applications while achieving weight reduction of at least 20% compared to solid SPC floorboards.
Solution Approach 2:
The patent uses composite material structure with multiple layers including foamed PVC core layer combined with surface layers containing calcium carbonate and PVC resin. This composite approach allows optimization of each layer for specific functions - the foamed core for weight reduction and the surface layers for durability and stability, achieving both lightweight and strong floorboard.
2Weight of moving object
If floorboard uses lightweight foamed structure to improve transportation convenience, then weight reduces, but mechanical properties such as elasticity modulus may deteriorate
Solution Approach 1:
The patent optimizes parameters of the foamed structure including cell size, cell wall thickness, and foam density to achieve the right balance between weight reduction and maintaining elasticity modulus. By controlling the foaming process parameters and material composition ratios, the floorboard achieves lightweight properties while preserving sufficient mechanical strength for installation and use.
Solution Approach 2:
The patent applies different material compositions and foam densities to different layers - the core layer uses foamed structure for weight reduction, while surface layers use denser composite materials with calcium carbonate and PVC resin to provide durability, scratch resistance, and maintain overall structural integrity and elasticity modulus.
3Device complexity
If floorboard uses single-layer structure for simplicity, then manufacturing process is simple, but high temperature stability deteriorates due to warping and shrinkage
Solution Approach 1:
The patent divides the floorboard into multiple functional layers including surface layers and core layer, with each layer having specific composition and function. This segmentation allows different layers to respond differently to temperature changes, with the foamed core providing dimensional stability and the surface layers providing environmental resistance, thereby reducing warping and shrinkage in high temperature environments.
Solution Approach 2:
The patent uses calcium-zinc stabilizers as intermediary substances that mediate between the PVC resin and environmental factors including heat. These stabilizers prevent degradation and dimensional changes of the PVC material under high temperature conditions, maintaining the stability of the multi-layer structure and preventing warping and shrinkage.
4Stability of the object's composition
If floorboard uses high calcium carbonate content to improve stability and reduce cost, then environmental adaptation improves, but toughness deteriorates
Solution Approach 1:
The patent concentrates high calcium carbonate content (80-100 parts by weight) in the core layer where it provides dimensional stability and environmental adaptation, while the surface layers contain PVC resin, stabilizers, and other additives that provide toughness and durability. This localized distribution allows each layer to excel at its primary function without compromising the other.
Solution Approach 2:
The patent creates composite material formulations in each layer - the core layer combines calcium carbonate with foaming agents for stability and weight reduction, while surface layers combine PVC resin with calcium-zinc stabilizers and other additives to provide toughness. The composite approach allows simultaneous achievement of stability from calcium carbonate and toughness from PVC resin in different layers.
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 improves static bending intensity, elasticity modulus, and reduces warping and shrinkage, achieving better stability and mechanical properties, with a weight reduction of at least 20% compared to conventional SPC floorboards, enhancing transportation and installation convenience.
Implementation Method 1
2-4 parts by weight of a first foaming aid
Implementation Method 2
2-4 parts by weight of a first calcium-zinc stabilizer
Data Source
AI summary
A multi-layer foamed floorboard and its preparation method are provided. The multi-layer foamed floorboard includes a surface layer and a core layer with a surface layer-core layer-surface layer structure. Raw materials of the surface layer include a first polyvinyl chloride (PVC) resin powder, a first calcium carbonate powder, a recycled material, a first calcium-zinc stabilizer, a first foaming aid, a toughening agent, a first internal lubricant, a first external lubricant and carbon black. Raw materials of the core layer include a second PVC resin powder, a second calcium carbonate powder, a foaming recycled material, a second calcium-zinc stabilizer, a second foaming aid, a foaming regulator, a yellow foaming agent, a white foaming agent, a second internal lubricant and a second external lubricant.