Primer Coated Substrates for Tile Adhesion
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Solution Overview
Problem
The luxury vinyl tile (LVT) industry faces challenges with adhesion between polypropylene-based wear layers and urethane-acrylic top coats, and existing adhesives do not provide sufficient bonding, leading to environmental concerns and processing complexities.
Innovation Solution
A composition comprising a functionalized olefin-based polymer and a functionalized styrenic block copolymer is used as a primer layer, which includes chemical groups such as carboxylic acid, anhydride, amino, or amine groups, and styrene, ethylene, and alpha-olefin, to enhance adhesion between the propylene-based wear layer and the urethane-acrylic top coat layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polypropylene-based wear layer is used, then scratch/abrasion resistance and flexibility are improved, but adhesion to urethane-acrylic top coat deteriorates
Solution Approach 1:
The patent applies a primer composition as an intermediary layer between the polypropylene wear layer and the urethane-acrylic top coat. This primer contains functionalized polymers with carboxylic acid and anhydride groups that chemically bond to both the polypropylene substrate and the urethane-acrylic coating, resolving the adhesion problem while preserving the scratch resistance of the polypropylene layer.
Solution Approach 2:
The patent modifies the chemical parameters of the primer composition by incorporating functionalized olefin-based polymers and functionalized styrenic block copolymers with specific chemical groups (carboxylic acid, anhydride). These parameter changes enable the primer to achieve compatible interactions with both the polypropylene wear layer and the urethane-acrylic top coat, solving the adhesion issue.
2Reliability
If conventional adhesion methods (surface treatment, blending) are used, then adhesion is improved, but processing complexity and time increase
Solution Approach 1:
The patent incorporates adhesion-promoting functional groups directly into the primer composition during manufacturing, rather than requiring subsequent surface treatments or modifications. This preliminary action eliminates the need for complex processing steps like plasma treatment, corona discharge, or chemical etching, while still achieving reliable adhesion.
Solution Approach 2:
The primer composition serves as a simplified intermediary that provides adhesion through its chemical composition rather than through complex processing treatments. This approach reduces device complexity and processing time while maintaining effective adhesion between layers.
3Reliability
If P-PVC is used for wear layer, then durability and appearance are improved, but environmental harm increases due to plasticizer emissions
Solution Approach 1:
The patent changes the material composition parameters by replacing P-PVC with polypropylene-based materials for the wear layer. This substitution eliminates plasticizer emissions while maintaining the required durability and appearance properties through the use of functionalized polymers and optimized composition.
Solution Approach 2:
The patent converts the potential harm of PVC by replacing it with environmentally friendly polypropylene-based materials. This substitution eliminates the harmful plasticizer emissions while maintaining or improving the performance characteristics through careful selection of polymer composition and functional groups.
4Strength
If P-PVC is used for wear layer, then wear resistance is improved, but recyclability and reprocessing capability deteriorate
Solution Approach 1:
The patent changes the material parameters by substituting P-PVC with polypropylene-based materials. This parameter change improves recyclability and reprocessing capability while maintaining wear resistance through the use of functionalized polymers and optimized material composition.
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 described composition achieves high adhesiveness and improved bonding between the propylene-based polymer and the urethane-acrylic material, providing a chlorine-free and efficient adhesive solution for Luxury Polyolefin Tiles (LPT), addressing environmental and processing issues.
Implementation Method 1
a functionalized olefin-based polymer comprising one or more chemical groups selected from the following: a) a carboxylic acid, and/or b) an anhydride, and, optionally, c) an amino or an amine
Data Source
AI summary
A tile comprising the following components: A) a first film formed from a first composition comprising the following: i) a functionalized olefin-based polymer comprising one or more chemical groups selected from the following: a) a carboxylic acid, and/or b) an anhydride, and, optionally, c) an amino or an amine; and ii) a functionalized styrenic block copolymer, comprising, in polymerized form, styrene, and ethylene and/or at least one alpha-olefin, and comprising one or more chemical groups selected from the following: a) a carboxylic acid, and/or b) an anhydride; and B) a substrate comprising at least one layer formed from a second composition comprising a propylene-based polymer; and wherein the first film covers at least one surface of the substrate.