Multi-layer PVC Flooring Adhesion via Dibutyl Sebacate Compatibilizer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing multi-layer floor coverings composed of polyvinyl butyrate (PVB) and polyvinyl chloride (PVC) face adhesion issues between layers due to the incompatibility of these polymers, leading to unsatisfactory adhesion strength.
Innovation Solution
Incorporating dibutyl sebacate (DBS) as a compatibilizing agent in both PVB and PVC layers, along with specific ratios of PVB and PVC, to enhance adhesion between layers, allowing for the integration of recycled PVB and PVC while maintaining the decorative and wear-resistant properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PVB and PVC are integrated into a multi-layer floor covering, then the floor covering gains improved adhesion and material compatibility, but the incompatibility between PVB and PVC polymers causes adhesion problems between layers
Solution Approach 1:
The patent uses dibutyl sebacate (DBS) as a compatibilizing agent that acts as an intermediary between PVB and PVC layers. DBS is incorporated into both PVB-containing and PVC-containing compositions, creating a chemical bridge that enables adhesion between the incompatible polymer layers. The lower layer contains 2-60 phr of DBS with 3-80 pcr of PVB, while the upper layer contains 2-60 phr of DBS with PVC, allowing the plasticizer to mediate interfacial adhesion.
Solution Approach 2:
The patent creates a composite multi-layer floor covering system where PVB and PVC layers are combined with specific compositional ratios and compatibilizing agents. The lower layer comprises PVB (3-80 pcr), PVC (100 pcr), and DBS (2-60 phr), while the upper layer comprises PVC and DBS (2-60 phr). This composite structure leverages the complementary properties of both polymers while managing their incompatibility through controlled composition.
2Adaptability or versatility
If recycled PVB is incorporated into the floor covering, then recyclability is enhanced and PVC quantity is reduced, but recycled PVB is generally not colored and may contain contaminants from previous applications
Solution Approach 1:
The patent recovers and reuses PVB from recycling sources (such as window films or automotive applications) in the lower layer of the floor covering. By incorporating 3-80 pcr of PVB into the composition with DBS as a compatibilizer, the patent enables the recovery of previously discarded PVB materials and gives them new utility in flooring applications, reducing waste and PVC dependency.
Solution Approach 2:
The patent applies different compositional qualities to different layers: the lower layer is designed to accommodate recycled, potentially uncolored PVB (3-80 pcr) mixed with PVC and DBS, while the upper layer maintains PVC-based composition (100 pcr) for decorative and functional performance. This local differentiation allows recycled material usage without compromising overall product quality.
3Ease of manufacture
If PVB is added as a tackifier to maintain contact with processing equipment, then processing adhesion is improved, but adhesion strength between PVB and PVC layers remains unsatisfactory
Solution Approach 1:
The patent employs dibutyl sebacate (DBS) as a dual-function intermediary that not only aids processing by maintaining contact with equipment but, more critically, enables adhesion between PVB and PVC layers. By incorporating DBS (2-60 phr) into both PVB-containing and PVC-containing compositions, the patent creates a compatibilizing system that addresses inter-layer adhesion, which simple tackification cannot achieve.
Solution Approach 2:
The patent gives DBS multiple functions: it acts as a plasticizer for PVB, a compatibilizing agent between PVB and PVC layers, and a processing aid for maintaining equipment contact. This multi-functionality allows a single additive to address multiple technical requirements simultaneously, including the critical inter-layer adhesion that single-function tackifiers cannot provide.
Data Source
AI summary
The invention relates to flooring which includes: a bottom layer containing, per hundred parts of polyvinyl chloride (phr): 3 to 80 phr of polyvinyl butyrate, 100 phr of polyvinyl chloride, 2 to 60 phr of dibutyl sebacate, and 1 to 200 phr of at least one additive; and a top layer including at least PVC and dibutyl sebacate.