Recycled Polyurethane Core for Curl-Resistant Resilient Planks
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Solution Overview
Problem
Vinyl-based engineered panels exhibit curling issues due to temperature changes, leading to panel decoupling, joint stress, and delamination, while lacking sufficient dimensional stability, acoustic insulation, and flexural strength.
Innovation Solution
A polyurethane core for engineered panels made from recycled materials, comprising polyol and isocyanate, with additives like calcium carbonate and chain extenders, providing improved dimensional stability and flexural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If vinyl-based polymers are used for panel cores, then ease of manufacture is improved, but dimensional stability deteriorates due to curling from thermal expansion and shrinking
Solution Approach 1:
The patent changes the material parameters by substituting vinyl-based polymers with polyurethane formulations containing specific additives (calcium carbonate, chain extenders) to achieve desired density and dimensional stability while maintaining ease of manufacture
Solution Approach 2:
The patent creates a composite material system by combining polyurethane with calcium carbonate filler and chain extenders, achieving both manufacturability and dimensional stability that neither component could achieve alone
2Productivity
If vinyl-based polymers are used for panel cores, then productivity is improved, but strength deteriorates due to insufficient flexural strength
Solution Approach 1:
The patent modifies the polymer formulation parameters by incorporating chain extenders and calcium carbonate to enhance flexural strength while maintaining production efficiency
Solution Approach 2:
The patent develops a composite polyurethane system with reinforcing additives that provides superior flexural strength compared to conventional vinyl-based cores, without compromising productivity
3Ease of manufacture
If conventional vinyl-based panels are used, then ease of manufacture is improved, but acoustic insulation deteriorates due to lacking sufficient acoustic insulation
Solution Approach 1:
The patent adjusts the core material parameters by incorporating calcium carbonate and optimizing polyurethane formulation to enhance acoustic insulation properties while maintaining ease of manufacture
Solution Approach 2:
The patent creates a composite material system that provides superior acoustic insulation compared to conventional vinyl panels, addressing the harmful factor of poor sound isolation
4Loss of substance
If polyurethane formulations with recycled materials are used, then environmental benefits are improved, but manufacturing precision may deteriorate due to variability in recycled material properties
Solution Approach 1:
The patent optimizes the formulation parameters to accommodate recycled materials, using specific ratios of polyol, isocyanate, and additives to achieve consistent results despite material variability
Solution Approach 2:
The patent uses calcium carbonate and chain extenders as intermediary components that help standardize the properties of recycled materials, ensuring consistent manufacturing precision
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 polyurethane core achieves reduced curling, enhanced dimensional stability, improved acoustic insulation, and increased flexural strength, while utilizing recycled materials to reduce plastic waste.
Implementation Method 1
comprising a polyol made, at least in part, from one or more recycled materials and an isocyanate
Data Source
AI summary
An exemplary embodiment of the present disclosure provides a polyurethane core for use in a floor or wall panel, the core comprising a polyol made, at least in part, from one or more recycled materials, and an isocyanate.