PHA Resin Cushion Flooring Eliminates Toxic Exposure
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Solution Overview
Problem
Conventional PVC-based cushion flooring materials are toxic and environmentally harmful due to the release of harmful substances when worn, and they fail to adequately address noise insulation between floors.
Innovation Solution
A cushion flooring material with a PHA resin-based elastic layer as the surface layer, comprising a copolymer of hard and soft segments, which is non-toxic, eco-friendly, and provides excellent sound insulation, combined with a cushioning and print layer structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a surface treatment layer is applied on top of the elastic layer to prevent scratches and contamination, then the durability and scratch resistance are improved, but the surface treatment layer becomes worn out over time to expose the underlying toxic PVC layer
Solution Approach 1:
The harmful PVC layer is completely removed from the flooring material structure. The patent extracts the toxic substance source by replacing the PVC-based elastic layer with a PHA resin-based elastic layer, while retaining the protective surface treatment layer structure. This eliminates the risk of toxic exposure when the surface layer wears out.
Solution Approach 2:
The patent converts the previously harmful PVC material into a beneficial PHA resin material that provides the same structural functions (elasticity, cushioning, surface protection) without the toxic properties. The PHA resin serves as a non-toxic substitute that maintains the protective function while eliminating the harm.
2Ease of manufacture
If conventional PVC materials are used for cushion flooring to provide basic flooring functions, then the structural requirements are met, but toxic substances are released during waste incineration and the materials remain permanently in landfills causing environmental pollution
Solution Approach 1:
The patent changes the fundamental chemical composition parameter of the elastic layer from PVC (polyvinyl chloride) to PHA (polyhydroxyalkanoate) resin. This parameter change transforms the material from non-biodegradable and toxic to biodegradable and non-toxic, while maintaining the necessary flooring functions such as elasticity, cushioning, and durability.
3Ease of manufacture
If traditional flooring materials are used to provide basic floor coverage, then the flooring function is achieved, but noise between floors becomes a serious social problem
Solution Approach 1:
The patent incorporates a foamed cushioning layer with porous structure between the balance layer and the elastic layer. This porous foam structure provides excellent sound insulation and noise reduction between floors, while maintaining the basic floor coverage function. The air pockets in the foam structure absorb sound waves and reduce noise transmission.
Data Source
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AI summary
The present invention relates to a cushion flooring material and a manufacturing method for the same and, more particularly, to a cushion flooring material and a manufacturing method for the same, which uses an elastic layer including a PHA resin alone or a composite resin including a PHA resin as a surface layer constituting the cushion flooring material to prevent toxic substances exposed to the user even if the surface layer is exposed due to wear of a surface treatment layer positioned on the surface layer, thereby making the cushion flooring material non-toxic, eco-friendly and excellent in sound insulation.