PVC-Free Polyurethane Rubber Sheet for Flooring
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Solution Overview
Problem
Existing homogeneous sheet products for flooring and wall coverings often rely on polyvinyl chloride (PVC), which may include plasticizers with unfavorable effects.
Innovation Solution
Development of compositions and methods to prepare PVC-free homogeneous sheets using a combination of thermoplastic polyurethane, synthetic rubber blend, and filler, which are extruded and cooled to form films or sheets, and can be further granulated and combined with other compositions for enhanced properties and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polyvinyl chloride (PVC) is used as the base material for homogeneous sheet products, then manufacturing process and material availability are improved, but health and environmental safety deteriorate due to plasticizers
Solution Approach 1:
The patent removes PVC and its associated plasticizers from the homogeneous sheet composition entirely, extracting the harmful substance while maintaining the product's functional requirements through alternative materials
Solution Approach 2:
The patent employs a composite material system combining thermoplastic polyurethane and synthetic rubber blend to replace PVC, achieving both safety requirements and manufacturing feasibility through material composition
2Object-affected harmful factors
If thermoplastic polyurethane and synthetic rubber blend are used to replace PVC, then health and environmental safety are improved, but manufacturing complexity increases
Solution Approach 1:
The patent modifies material parameters by selecting specific ratios of thermoplastic polyurethane (60-80 wt%) and synthetic rubber blend (20-40 wt%), optimizing the composition to balance safety performance with manufacturing ease
Solution Approach 2:
The thermoplastic polyurethane-synthetic rubber composite system performs multiple functions simultaneously: providing safety without plasticizers, maintaining flexibility and hardness, and enabling standard extrusion manufacturing processes
3Reliability
If homogeneous sheet is made without PVC, then product safety is improved, but material selection and formulation complexity increase
Solution Approach 1:
The patent applies local quality by specifying particular property ranges for each component: thermoplastic polyurethane with specific hardness and flexibility characteristics, and synthetic rubber blend with complementary properties, creating a balanced formulation
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 PVC-free sheet product with improved properties such as hardness and flexibility, and reduced smoke production, making it suitable for commercial use as flooring or wall coverings.
Implementation Method 1
extruding the sheet components through a die or calender into a film and cooling
Implementation Method 2
extruding the sheet components through a die or calender into a film and cooling
Data Source
AI summary
Included is a homogeneous sheet, which excludes polyvinylchloride. The sheet includes a polyurethane, a synthetic rubber blend, and a filler. The synthetic rubber blend may include a pre-mix of a synthetic rubber and white oil.