PVC Floor Covering Low Toxic Fume Emission
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Solution Overview
Problem
PVC floor coverings emit high levels of toxic hydrochloric acid during fires, posing a challenge for their use in passenger transport vehicles due to strict emission standards, and existing alternatives lack the wear resistance, flexibility, and cleanability of conventional PVC floors.
Innovation Solution
A floor covering composition that includes polyvinyl chloride with a polymeric plasticizer, which replaces traditional plasticizers and acts as a binder, reducing hydrochloric acid emissions while maintaining flexibility and allowing for increased use of additives like fillers and flame retardants, thereby enhancing wear resistance and cleanability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional non-polymeric plasticizers (e.g., DIDP, DPO) are used in PVC floor coverings, then the composition achieves good flexibility, but it emits high levels of hydrochloric acid during fires and requires increasing quantities to maintain flexibility
Solution Approach 1:
The patent changes the chemical nature of the plasticizer from traditional non-polymeric types (phthalates, phosphates) to polymeric plasticizers with specific molecular structures (polyester polymers, polyether polymers, polycarbonate polymers). This parameter change in plasticizer chemistry reduces hydrochloric acid emissions during combustion while maintaining flexibility through the polymeric structure's interaction with PVC
Solution Approach 2:
The invention creates a composite plasticizer system combining polymeric plasticizers with specific functional groups that provide both flexibility enhancement and reduced toxic emissions. The composite approach allows synergistic effects where the polymeric structure provides flexibility while the specific chemical composition reduces hydrochloric acid release during fires
2Object-affected harmful factors
If polyvinyl butyral is added to reduce toxic emissions, then hydrochloric acid emissions decrease, but the quantity of liquid plasticizers must be increased which increases exudation risk and reduces stability
Solution Approach 1:
The patent replaces traditional liquid plasticizers with polymeric plasticizers that have lower volatility and reduced exudation tendencies. The polymeric structure acts as a long-term stable component that doesn't migrate or evaporate easily, eliminating the stability issues associated with increasing liquid plasticizer quantities
Solution Approach 2:
The invention changes the physical state and molecular weight parameters of the plasticizer from low-molecular-weight liquids to high-molecular-weight polymers. This parameter change reduces volatility and migration properties, thereby preventing exudation and maintaining composition stability over time while still providing necessary flexibility
3Object-affected harmful factors
If PVC is replaced by halogen-free polymers (e.g., ethylene/octene copolymer, polypropylene), then hydrochloric acid emissions are eliminated, but wear resistance, flexibility, and cleanability properties are lost
Solution Approach 1:
The patent modifies the PVC composition by incorporating polymeric plasticizers that alter the thermal and mechanical parameters of the material. This allows the PVC to maintain its inherent wear resistance and flexibility properties while the reduced chlorine content or modified combustion characteristics lower hydrochloric acid emissions during fires
Solution Approach 2:
The invention creates a composite PVC formulation combining PVC resin with specific polymeric plasticizers and flame retardant additives. This composite approach preserves the mechanical strength and wear resistance of PVC while the additive package reduces toxic emissions, achieving both performance and safety requirements
4Ease of operation
If the quantity of liquid plasticizers is increased to maintain flexibility, then flexibility is improved, but exudation risk increases and stability over time is reduced
Solution Approach 1:
The patent replaces transient liquid plasticizers with stable polymeric plasticizers that do not migrate or evaporate. The polymeric structure provides long-term stability by being locked within the PVC matrix, eliminating the need for continuous replenishment and preventing exudation issues
Data Source
Figure 1~3
AI summary
The invention relates to a PVC floor covering with low toxic fume emission comprising at least one layer whose composition includes polyvinyl chloride, and a plasticizer composed at least partly of a polymeric plasticizer at least partly miscible with polyvinyl chloride.