PLA Resin Flooring Material with Acrylic Copolymer Melt Strength
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Solution Overview
Problem
The challenge lies in the supply of raw materials for flooring materials, particularly the use of petroleum-based PVC, which faces depletion and generates toxic substances, posing environmental concerns.
Innovation Solution
A flooring material utilizing polylactic acid (PLA) resin with a base layer, print layer, and transparent layer, incorporating non-phthalate plasticizers and acrylic copolymers to enhance melt strength and facilitate processing, while minimizing toxic emissions and incorporating natural wood flour for texture and fragrance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If PVC resin is used for flooring material, then manufacturing processability is good, but raw material supply becomes problematic due to petroleum exhaustion
Solution Approach 1:
The patent changes the chemical composition parameter from petroleum-based PVC to plant-based PLA resin, maintaining thermoplastic properties while transitioning to renewable resources. The addition of plasticizers and acrylic copolymers adjusts the material parameters to achieve comparable processability to PVC.
Solution Approach 2:
The patent introduces plasticizers and acrylic copolymers as intermediary substances to mediate between the inherent brittleness of pure PLA and the desired flexibility and processability of PVC. These intermediaries enable the PLA-based material to achieve comparable manufacturing characteristics.
2Strength
If PVC resin is used for flooring material, then structural properties are sufficient, but toxic substances are generated during use and disposal
Solution Approach 1:
The patent converts the potential weakness of PLA (lower inherent strength compared to PVC) into an advantage by using biodegradability and non-toxicity as beneficial features. The material's ability to decompose naturally and not generate toxic substances during disposal transforms an environmental harm into a beneficial ecological feature.
Solution Approach 2:
The patent creates a composite material system combining PLA resin with plasticizers and acrylic copolymers to achieve the necessary structural properties. This composite approach allows the material to meet strength requirements while maintaining the environmental benefits of PLA, avoiding the toxic issues associated with pure PVC.
3Object-generated harmful factors
If PLA resin is used without additives, then environmental friendliness is achieved, but melt strength is insufficient for calendering and pressing
Solution Approach 1:
The patent introduces acrylic copolymers as intermediary substances that act as melt strength enhancers. These copolymers mediate between the environmental requirements (minimal additives) and processing requirements (sufficient melt strength), allowing calendering and pressing operations to proceed effectively while maintaining environmental friendliness.
Solution Approach 2:
The patent modifies the material parameters by adding controlled amounts of plasticizers and acrylic copolymers to PLA resin. This changes the melt flow characteristics and strength parameters, enabling the material to withstand calendering and pressing processes while retaining the base environmental benefits of PLA.
Data Source
Figure 1~4
AI summary
Disclosed is a flooring material using an environment-friendly PLA resin. According to the present invention, the flooring material using the PLA resin comprises: a base layer; a print layer which is formed on top of the base layer, and has a print pattern on an upper side thereof; and a transparent layer which is formed on top of the print layer, wherein one or more of the base layer, the print layer, and the transparent layer include polylactic acid (PLA) resin.