PVC Composite Foaming Agent Synergy for Sound Reduction
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Solution Overview
Problem
Existing PVC foam boards suffer from inadequate foaming, insufficient strength and toughness, instability due to decomposition under light and heat, and surface scratching issues, making them unsuitable for stable and easy installation as flooring.
Innovation Solution
A PVC composite material formulation comprising 40-60 parts by weight of PVC, 40-60 parts by weight of calcium carbonate, 0.2-0.6 parts by weight of composite foaming agent, 3-5 parts by weight of foam regulator, 2-4 parts by weight of toughener, 0.8-1.2 parts by weight of lubricant, and 2-3 parts by weight of stabilizer, along with optional brightening agents and plant fibers, which improves foaming, strength, hardness, and stability, and prevents surface scratching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single foaming agent is used in PVC foam board production, then the production process is simple, but the foaming effect is inadequate and uneven, failing to achieve sound reduction
Solution Approach 1:
The patent combines multiple foaming agents (organic foaming agent and inorganic foaming agent) into a composite foaming system. The organic foaming agent provides initial foam formation while the inorganic foaming agent ensures uniform and sustained foaming, achieving both simple process operation and excellent foaming effect with sound reduction capabilities.
Solution Approach 2:
The patent uses a composite foaming agent system consisting of different types of foaming agents (organic and inorganic) that work synergistically. This composite approach ensures adequate and uniform foaming effect while maintaining production process simplicity, resolving the contradiction between manufacturing ease and foaming performance.
2Strength
If traditional PVC formulation is used, then the production cost is low, but the strength, hardness and toughness of the boards are insufficient, shortening service life
Solution Approach 1:
The patent optimizes the quantities and ratios of supplementary materials (toughener, lubricant, stabilizer, foaming agent) to achieve the desired balance between strength, hardness, toughness and cost. By precisely controlling these parameters within specific ranges, the patent improves board performance without excessive material consumption.
Solution Approach 2:
The patent employs a composite formulation system combining PVC with multiple supplementary materials (toughener, lubricant, stabilizer, foaming agent, brightening agent) in optimized proportions. This composite material system achieves superior strength, hardness and toughness while controlling production costs through efficient material utilization.
3Ease of operation
If PVC material is used for flooring, then the flooring has resilient properties, but the requirements for subfloor flatness are much higher, improving installation difficulty
Solution Approach 1:
The patent modifies the physical and mechanical parameters of PVC flooring through optimized formulation (adding toughener, lubricant, stabilizer, and foaming agents) to reduce the flooring's sensitivity to subfloor irregularities. This allows resilient flooring to be installed on substrates with lower flatness requirements, easing installation while maintaining comfort properties.
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 improved PVC composite material achieves even foaming for sound reduction, enhanced strength and toughness, stability against decomposition, and reduced surface scratching, facilitating easier installation and increased market share.
Implementation Method 1
a mixture of PVC, a foaming agent and the like is foamed at high temperature
Implementation Method 2
an inorganic foaming agent of the composite foaming agent may be sodium bicarbonate, an organic foaming agent of the composite foaming agent may be azodicarbonamide (AC)
Implementation Method 3
PVC is likely to be decomposed under light and heat conditions, so the properties of the products are not stable
Implementation Method 4
0.8-1.2 parts by weight of lubricant
Data Source
AI summary
A polyvinyl chloride polymer (PVC) composite material is described herein. The PVC composite material includes 40-60 parts by weight of PVC, 40-60 parts by weight of calcium carbonate, 0.2-0.6 parts by weight of composite foaming agent, 3-5 parts by weight of foam regulator, 2-4 parts by weight of toughener, 0.8-1.2 parts by weight of lubricant, and 2-3 parts by weight of stabilizer. Meanwhile, the present invention provides a foam board made of the PVC composite material and flooring. The resulting PVC products have a high-strength structure and a good foaming property, bring the comfort to feet as the resilient flooring does, have a satisfied sound reduction and can be easily installed as the hard flooring could.