PVC Floor Covering Structure With Woven Reinforcement for Recyclability
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Solution Overview
Problem
Existing multilayer floor coverings for aircraft floors are costly to produce, require technical expertise, are not recyclable due to the use of thermosetting resins, and lack sufficient resistance to deformation and telegraphing, while existing alternatives compromise on recyclability or performance.
Innovation Solution
A multilayer structure comprising a surface layer bonded to a backing layer made of PVC, with woven reinforcements and intermediate layers, using heat-fusible films and cross-linked adhesives, to ensure adhesion, dimensional stability, and impact resistance, while being recyclable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a laminated backing layer with woven fiberglass reinforcement impregnated with phenolic or polyester resins is used, then adhesion to substrate, dimensional stability, and impact resistance are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention divides the backing layer into two separate layers: a first PVC layer (0.5-2.0 mm thick) and a second PVC layer (0.1-0.5 mm thick). This segmentation simplifies manufacturing compared to traditional laminated structures while maintaining the required mechanical properties. Each layer can be processed independently using standard PVC extrusion and lamination equipment.
Solution Approach 2:
The invention changes the material parameter from phenolic/polyester resins to PVC with controlled plasticizer content (5-25 parts per hundred resin). This parameter change maintains adhesion and impact resistance while enabling recyclability and simplifying manufacturing. The specific gravity of the backing layer is controlled between 1.30-1.60 to optimize performance.
2Stability of the object's composition
If phenolic resin is used in the backing layer, then adhesion and dimensional stability are improved, but recyclability is lost
Solution Approach 1:
The invention changes the chemical composition parameter by replacing phenolic resin with PVC and controlling plasticizer content at 5-25 parts per hundred resin. This allows the material to be thermoplastic and recyclable while maintaining dimensional stability through the controlled plasticizer level and multi-layer structure.
Solution Approach 2:
The invention uses a composite structure with two PVC layers having different plasticizer contents. The first layer has 5-25 parts plasticizer and the second layer has 15-35 parts plasticizer, creating a composite material that achieves both dimensional stability and recyclability.
3Ease of manufacture
If thermoplastic resin is used instead of thermosetting resin, then recyclability is improved, but structural performance and resistance to deformation deteriorate
Solution Approach 1:
The invention creates a composite structure with two PVC layers of different formulations. The first layer (0.5-2.0 mm) has 5-25 parts plasticizer for structural integrity, while the second layer (0.1-0.5 mm) has 15-35 parts plasticizer for flexibility. This composite approach maintains resistance to deformation while ensuring recyclability.
Solution Approach 2:
The invention incorporates woven reinforcement fabric in the first PVC layer to provide structural strength and resistance to deformation. The reinforcement creates a composite material that behaves like a thermosetting structure but remains recyclable as thermoplastic PVC.
4Ease of operation
If plasticizer content is increased to improve flexibility, then ease of installation is improved, but resistance to telegraphing and buckling deteriorates
Solution Approach 1:
The invention segments the plasticizer distribution into two layers: the first layer has lower plasticizer content (5-25 parts) for stability and telegraphing resistance, while the second layer has higher plasticizer content (15-35 parts) for flexibility and ease of installation. This segmentation allows both requirements to be satisfied simultaneously.
Solution Approach 2:
The invention applies local quality by giving different plasticizer concentrations to different layers. The first layer near the substrate has lower plasticizer for stability, while the second layer at the surface has higher plasticizer for workability. This local differentiation optimizes both installation ease and performance.
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 cost-effective, recyclable, and high-performance floor covering with improved resistance to deformation and telegraphing, maintaining adhesion and structural integrity.
Implementation Method 1
bonding layers in the form of heat-fusible films
Implementation Method 2
cross-linked adhesives
Implementation Method 3
the migration of plasticizers from the PVC surface layers
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a multilayer structure (1) for the production of a floor covering, comprising at least one surface layer (2) bonded to a backing layer (3b), the surface layer (2) and the backing layer (3b) being made from PVC, the multilayer structure (1) comprising successively and from top to bottom, between the surface layer (2) and the backing layer (3b), a first woven reinforcement (5a), an intermediate layer (3a), a second woven reinforcement (5b), bonded together, to the surface layer (2) and to the backing layer (3b) by means of bonding layers (6) in the form of hot-melt films, for example, in copolyamide or copolyester, or of cross-linked polyurethane adhesive layers, the multilayer structure (1) comprising a surface mass of between 2000 and 3000 g/m2,The intermediate layer (3a) and the reverse layer (3b) are made from PVC and each comprises: - a thickness between 100 µm and 200 µm; - between 5 and 25 PCRs of plasticizer, preferably between 6 and 15 PCRs of plasticizer.