Multi-Layer Ionomer Laminate for Heat Resistance and Pattern Realism
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Solution Overview
Problem
Conventional laminate flooring technologies face challenges in achieving natural pattern realism, heat resistance, and compatibility of multiple layers, limiting their durability, aesthetic appeal, and usability in applications like prosthetic sockets and curved surfaces.
Innovation Solution
A laminate covering comprising multiple layers, including a durable and chemically resistant surface layer, a functional decorative layer, and a structural layer, with tie layers for adhesion, which are thermoformable and can incorporate features like luminescence, thermochromism, and scratch resistance, using materials such as ionomers, polyurethanes, and thermoplastic adhesives, allowing for enhanced weatherability and aesthetic effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polyvinyl chloride resin is used as a skin layer to protect the printing layer, then durability is improved, but yellowing occurs due to heat changes during processing and heat resistance deteriorates
Solution Approach 1:
The patent changes the material parameter from polyvinyl chloride resin to ionomer resin, which has a higher melting point and better heat resistance. This parameter change eliminates yellowing during processing while maintaining durability, as ionomer resin can withstand higher temperatures without degrading or discoloring.
Solution Approach 2:
The patent uses composite material structure with multiple layers including ionomer resin as the skin layer combined with decorative layers. This composite approach allows the ionomer resin to provide both protection and heat resistance, solving the contradiction between durability and heat stability.
2Manufacturing precision
If conventional printing methods are used on polyvinyl chloride resin sheets, then pattern transfer is achieved, but pattern realism deteriorates due to artificial traces and filler deterioration
Solution Approach 1:
The patent changes the substrate material parameter from polyvinyl chloride resin to ionomer resin, which provides a smoother surface that better accepts photographic images. This eliminates the need for fillers that cause deterioration, thereby improving pattern realism while maintaining manufacturing precision.
Solution Approach 2:
The patent uses direct photographic applique printing on the ionomer resin surface, creating a more accurate copy of the original image without the distortion and artificial traces that occur with conventional transfer methods on polyvinyl chloride resin.
3Ease of manufacture
If polyvinyl chloride resin with low softening point is used, then ease of processing is improved, but heat resistance deteriorates due to poor resistance to heat sources over 100° C.
Solution Approach 1:
The patent changes the thermal parameter of the material by substituting polyvinyl chloride resin (softening point 80-100°C) with ionomer resin (melting point above 100°C). This parameter change maintains processability while significantly improving heat resistance to withstand heat sources over 100°C.
4Adaptability or versatility
If multiple layers with different functionalities are combined, then versatility is improved, but layer compatibility deteriorates making it difficult to bond different materials
Solution Approach 1:
The patent uses tie layers as intermediary bonding layers between the ionomer resin skin layer and the decorative layers. These tie layers are specifically designed to bond to both the ionomer resin and the decorative materials, ensuring layer compatibility and stability while maintaining the multi-functional versatility of the laminate structure.
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 provides laminates with improved weather resistance, fade resistance, scratch resistance, and aesthetic appeal, enabling their use in diverse applications, including prosthetic sockets, outdoor furniture, and automotive components, while being thermoformable for curved surfaces.
Implementation Method 1
a tie layer between the inner layer and the outer layer
Implementation Method 2
The inner layer can include a plurality of layers, where the plurality of layers includes a graphic carrier film layer having a decorative printed graphics, and a thermal insulator layer selected from at least one of thermoplastic urethane with fillers, blowing agents, luminescent additives, and combinations thereof
Implementation Method 3
Some layers of this laminate product could also provide additional functionality such as thermochromism
Data Source
AI summary
Laminate coverings having multiple layers with different functionalities for various applications including prosthetic, outdoor furniture and automotive cargo/trunk liner and floor mat applications. In some instances, the laminate coverings may also be used as decorative skins or be used in other applications for its decorative or aesthetic properties, the laminate coverings having improved UV, weatherability, scratch and mar resistance, among other enhancements.