Multilayer Resilient Flooring with Cellulose Ester Combustion Suppression

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Solution Overview

Problem

Current technologies face challenges in utilizing cellulose esters in plastic compositions due to processing difficulties, such as a narrow temperature window between melting and decomposition points, limiting their use in injection molded articles and film/sheet production, and their absence in resilient flooring applications where environmentally-friendly alternatives to polyvinylchloride are sought.

Innovation Solution

A multilayer resilient flooring article is developed using a core and top layer of plasticized cellulose ester-based compositions, with the inclusion of a mineral-based water releasing agent or phosphorus flame retardant as a combustion suppression system, allowing for improved flammability, smoke suppression, and processability comparable to polyvinyl chloride flooring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If cellulose esters are used in plastic compositions, then environmentally-friendly alternatives to polyvinylchloride are provided, but processing difficulties arise due to narrow temperature window between melting and decomposition points

Engineering Contradiction:

Improveenvironmentally-friendly alternativeVSAvoidprocessing difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent modifies processing parameters including using a two-stage extrusion process with controlled temperature zones, adjusting screw speed and pressure to maintain cellulose ester within a safe temperature window while achieving proper melting and mixing

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces a protective atmosphere (nitrogen or carbon dioxide) as an intermediary medium during processing to prevent thermal decomposition of cellulose ester while maintaining stable processing conditions

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If cellulose esters are used in resilient flooring, then environmentally-friendly flooring is achieved, but flammability and smoke generation issues arise

Engineering Contradiction:

Improveenvironmentally-friendly flooringVSAvoidflammability and smoke generation

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent creates composite materials by combining cellulose ester with flame retardant additives and potentially other polymers to achieve both environmental friendliness and improved fire resistance, balancing ecological benefits with safety requirements

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent converts the natural combustibility of cellulose ester into a benefit by using controlled combustion suppression mechanisms that release water vapor upon heating, creating a protective barrier that prevents flame spread while maintaining the base material's environmental advantages

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Object-affected harmful factors

If multilayer structure is used with transparent top layer, then UV transmission to print layer is minimized, but processing complexity increases

Engineering Contradiction:

ImproveUV transmission protectionVSAvoidmultilayer structure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent divides the flooring into distinct functional layers: a transparent UV-blocking top layer and a print layer underneath, where each layer is optimized for its specific function while being processed as an integrated multilayer structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The top layer is designed to perform multiple functions simultaneously: providing UV protection, maintaining aesthetic transparency, and serving as a wear-resistant surface, thereby reducing the need for additional specialized layers

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 commercially acceptable smoke generation and flame resistance, while maintaining the balance of composition processability and end-product resiliency, with a corrected smoke density of 450 or less and flexural modulus and impact strength meeting commercial standards.

Implementation Method 1

a core and top layer of plasticized cellulose ester-based compositions, with the inclusion of a mineral-based water releasing agent or phosphorus flame retardant as a combustion suppression system

Methodology Applied

Scientific EffectWater releasing agent: Endothermic Reaction

Implementation Method 2

a core and top layer of plasticized cellulose ester-based compositions, with the inclusion of a mineral-based water releasing agent or phosphorus flame retardant as a combustion suppression system

Methodology Applied

Scientific EffectFlame retardant: Combustion

Data Source

PatentUS20230330971A1Multilayer resilient flooring article

Publication Date: 2023.10.19 EASTMAN CHEM CO

AI summary

Disclosed is a multilayer resilient flooring article, The multilayer resilient flooring article of the present invention includes a core layer comprising a first plasticized cellulose ester-based composition and a top layer comprising a second plasticized cellulose ester-based composition, wherein the first plasticized cellulose ester-based composition comprises a combustion suppression system. Compositions useful for example in the manufacture of multilayer resilient flooring articles are also described.