Non-PVC Surface Covering with Polyolefin Abrasion-Resistant Layer
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Solution Overview
Problem
Conventional PVC surface coverings suffer from deformation issues due to unbalanced thermal contraction between layers, and they pose environmental concerns due to toxic by-products and heavy metal hazards, while alternative materials like ionic polymers and copolyesters have poor market acceptance and dimensional stability.
Innovation Solution
A non-PVC surface covering with a multi-layer structure comprising a bottom material layer, a middle layer, and a transparent abrasion-resistant layer, where the transparent abrasion-resistant layer is composed of 40-94.95 wt% polyolefin, 5-40 wt% polyolefin elastomer or plastomer, and 0.05-10 wt% processing agent, ensuring balanced thermal contraction and improved abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PVC is used as the material for surface coverings, then good processing properties, excellent flame retardant properties, and good mechanical properties are achieved, but environmental concerns arise due to toxic by-products and heavy metal hazards
Solution Approach 1:
The patent changes the material composition parameters by replacing PVC with polyolefin-based materials, eliminating toxic plasticizers and heavy metal stabilizers while maintaining mechanical properties through optimized polymer blends and processing conditions
Solution Approach 2:
The patent uses readily available polyolefin materials that are environmentally friendly and can be processed efficiently, replacing expensive or environmentally harmful materials while maintaining cost-effectiveness
2Stability of the object's composition
If the thickness of the bottom material layer is increased or the amount of PVC in the bottom material layer is enhanced to balance contraction, then dimensional stability is improved, but the deformation problem persists due to unbalanced thermal contraction
Solution Approach 1:
The patent changes the thermal contraction parameters by selecting polyolefin materials with matched thermal contraction coefficients for all layers, eliminating the need to increase layer thickness or PVC content while achieving dimensional stability
Solution Approach 2:
The patent uses composite polyolefin materials with specifically selected thermal properties in each layer to achieve balanced thermal contraction across the multi-layer structure, preventing warping and arching
3Object-generated harmful factors
If ionic polymers and copolyesters are used as substitute materials for PVC, then environmental friendliness is improved, but high price and poor dimensional stability reduce market acceptance
Solution Approach 1:
The patent uses cost-effective polyolefin materials that are environmentally friendly and widely available, avoiding the high cost of ionic polymers and copolyesters while achieving comparable or superior performance
Solution Approach 2:
The patent optimizes the thermal contraction parameters of polyolefin materials to achieve dimensional stability, overcoming the poor dimensional stability issue of alternative materials like ionic polymers
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 significantly reduces deformation and enhances dimensional stability and abrasion resistance, while being environmentally friendly and cost-effective, with average warping reduced to less than 0.6 mm and dimension change to less than 0.05%, outperforming PVC surface coverings in wear-resistance testing.
Implementation Method 1
because the structure of each layer has a different thermal contraction, unbalanced contraction occurs during the hot pressing process and leads to a deformation of the resulting multi-layer structure
Data Source
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AI summary
A non-polyvinylchloride (non-PVC) surface covering is provided. The non-PVC surface covering includes a bottom material layer. A middle layer is disposed on the bottom material layer, wherein the middle layer includes a middle material layer. A transparent abrasion-resistant layer is disposed on the middle layer, wherein the transparent abrasion-resistant layer includes a polyolefin of 40∼94.95 wt%, a polyolefin elastomer (POE) or a polyolefin plastomer (POP) of 5∼50 wt%, and a processing agent of 0.05∼10 wt%.