Polypropylene Composite Floor for Toxic-Free Dimensional Stability
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Solution Overview
Problem
Traditional PVC-based composite floors face issues such as toxic gas emission, reproductive toxicity, poor dimensional stability, and high production costs due to low production efficiency, along with problems like poor transparency, scratch resistance, and compactness between layers.
Innovation Solution
A polypropylene-based composite floor structure comprising a scratch-resistant layer, a super-transparent wear-resistant layer, a decorative layer, and substrate layers with specific material formulations and processing methods, including surface-polarizing treatments and thermal transfer processes, to enhance mechanical strength, transparency, and production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If PVC-based materials are used for composite floors, then the floors have good dimensional stability and mechanical strength, but they release toxic gases and contain phthalate plasticizers that produce reproductive toxicity
Solution Approach 1:
The patent changes the material parameter from PVC to polypropylene, fundamentally altering the chemical composition to eliminate toxic emissions while maintaining structural performance through optimized polypropylene formulation and processing parameters
Solution Approach 2:
The patent uses composite material structure with multiple layers (wear-resistant layer, decorative layer, substrate layer) where polypropylene serves as the base material, combining environmental friendliness with mechanical strength and dimensional stability through layer-specific functional design
2Productivity
If traditional extrusion or casting processes are used for non-PVC composite floors, then the production capacity is limited and product cost is considerably high
Solution Approach 1:
The patent merges multiple manufacturing steps into a one-step co-extrusion process, combining the formation of wear-resistant layer, decorative layer, and substrate layer into a single continuous operation, thereby increasing production capacity and reducing costs
Solution Approach 2:
The patent optimizes processing parameters including temperature ranges (200-300°C), pressure conditions, and extrusion speeds to enable efficient high-volume production while maintaining product quality
3Object-affected harmful factors
If non-PVC materials are used for composite floors, then environmental problems and plasticizer separating-out problems are solved, but the wear-resistant layer has poor transparency
Solution Approach 1:
The patent controls crystallization parameters including cooling rate, nucleating agent concentration, and processing temperature to reduce crystal size and density, thereby improving light transmission while maintaining the environmental benefits of polypropylene
Solution Approach 2:
The patent introduces nucleating agents as intermediaries that control crystal formation during cooling, creating a fine crystalline structure that allows light to pass through more effectively while maintaining the non-toxic polypropylene base material
4Object-affected harmful factors
If non-PVC composite floors are manufactured, then environmental issues are resolved, but the floors exhibit poor dimensional stability, scratch-resistance, and compactness between layers
Solution Approach 1:
The patent creates a composite structure with functionally differentiated layers where each layer is optimized for specific properties: wear-resistant layer for scratch resistance, decorative layer for appearance, and substrate layer for dimensional stability, all while maintaining environmental safety through polypropylene base material
Solution Approach 2:
The patent optimizes processing parameters including layer thickness ratios, extrusion temperatures, and cooling rates to ensure proper bonding between layers and maintain dimensional stability throughout the product lifecycle
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 provides a lightweight, environmentally friendly composite floor with excellent dimensional stability, mechanical strength, and improved production efficiency, addressing the limitations of PVC-based floors by ensuring good compactness and scratch resistance without additional connective layers.
Implementation Method 1
The transparent wear-resistant layer is formed from raw materials containing polypropylene and a nucleating agent, and has a haze of less than 11% and a light transmittance of more than 90%
Implementation Method 2
excellent compactness between each layer and its neighboring layer without using additional connective layer
Data Source
Figure 1
AI summary
The present invention provides is a lightweight environment-friendly polypropylene composite floor comprising, from top to bottom: 1) a scratch-resistant coating layer, 2) a super-transparent wear-resistant layer, 3) a decorative layer, 4) a first substrate layer, 5) a second substrate layer, 6) a bottom connective layer, and optionally 7) a back adhesive layer. Also provided is a preparation process of the composite floor.