Peroxide-Cured Polyolefin Flooring for Heat Stability
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Solution Overview
Problem
Rubber flooring products made from SBR, NR, or NBR suffer from heat instability during processing and curing, leading to discoloration and color shading issues, which affect their aesthetic and physical properties.
Innovation Solution
A new formula incorporating a polyolefin-based elastomer, a polyolefin-based thermoplastic material with an ionomer, and a peroxide curing system, which provides improved heat resistance and color retention, allowing for the production of flooring materials that maintain their color and exhibit enhanced physical features like flexibility and abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional rubber materials (SBR, NR, NBR) are used for flooring products, then the material provides good elasticity and cushioning, but it suffers from heat instability during processing and curing that causes discoloration and color shading
Solution Approach 1:
The patent changes the chemical composition parameters by replacing traditional sulfur-cured rubber with a peroxide-cured polyolefin-based elastomer system. This parameter change eliminates the heat instability and discoloration issues while maintaining the desired elastic properties, achieving both heat stability and color control during processing
Solution Approach 2:
The patent uses a composite material system combining polyolefin-based elastomer, polyolefin-based thermoplastic material with ionomer, and peroxide curing system. This composite approach provides both the thermal stability needed for processing and the color consistency required for manufacturing quality
2Strength
If sulfur curing system is used for rubber flooring, then the material achieves good vulcanization and physical properties, but it becomes unstable at processing and curing temperatures leading to discoloration
Solution Approach 1:
The patent changes the curing mechanism parameter from sulfur-based vulcanization to peroxide-based curing. This parameter change allows the material to achieve proper crosslinking and physical properties without the heat instability and discoloration problems associated with sulfur curing at processing temperatures
Solution Approach 2:
The patent extracts and removes the sulfur curing system from the formulation, replacing it with a peroxide curing system that does not suffer from heat-induced discoloration. This extraction eliminates the harmful thermal reactions while preserving the beneficial vulcanization effects
3Reliability
If traditional rubber flooring materials are used, then the material provides adequate durability, but it shows poor color retention over time and under heat exposure
Solution Approach 1:
The patent employs a composite material formulation with polyolefin-based elastomer, thermoplastic material with ionomer, and peroxide curing system that works synergistically to provide both long-term durability and excellent color retention, overcoming the limitations of traditional rubber materials
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 new formula results in flooring materials that are heat-stable, maintain their color over time, and offer improved physical properties such as flexibility and abrasion resistance, enabling the creation of lighter, brighter, and more durable rubber flooring products.
Implementation Method 1
a peroxide curing system capable of causing interlinking reactions to take place when the material is cured
Data Source
AI summary
In various embodiments, the present inventions provide a heat and color stable flooring materials/product comprising between about 1 wt% to about 50 wt% a polyolefin- based elastomer material; between about 2 wt% to about 50 wt% a polyolefin-based thermoplastic material; between about 20 wt% to about 75 wt% a filler; and between about 0.25 wt% to about 5 wt% a curing system containing a peroxide. Also provided in various embodiments are method of making and using such a flooring material/product.