Renewable Polyurethane Floor Covering Without PVC or Phthalates
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Solution Overview
Problem
Current floor coverings made from PVC and other materials face issues such as reliance on non-renewable fossil energy, presence of chlorine and phthalates, long maturation times, and inferior mechanical properties, while alternatives like linoleum have limited pattern diversity and fragility.
Innovation Solution
A floor covering is developed using a reaction between ricinoleic acid from castor oil or glycerol and an isocyanate, forming a polyurethane layer that is crosslinked, offering improved mechanical properties and ease of manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If PVC and plasticized polyvinyl chloride are used for floor coverings, then mechanical properties and ease of manufacture are improved, but harmful factors (chlorine, phthalates) and non-renewable resources are increased
Solution Approach 1:
The invention extracts and eliminates harmful components (chlorine, phthalates) from the floor covering formulation by completely replacing PVC with a polyurethane system based on vegetable oil polyols and isocyanates, achieving a harmful-factor-free material while maintaining mechanical performance
Solution Approach 2:
The invention changes the chemical composition parameters by using polyols with specific hydroxyl values (50-200 mg KOH/g) derived from vegetable oils and reacting them with isocyanates in controlled NCO/OH ratios (0.8-1.2) to produce polyurethanes with equivalent or superior mechanical properties to PVC without harmful additives
2Quantity of substance
If linoleum is synthesized from vegetable oil, then renewable raw materials are used, but maturation time and manufacturing duration are increased
Solution Approach 1:
The invention performs preliminary action by pre-synthesizing polyols from vegetable oils with controlled molecular weights and hydroxyl values before the final polyurethane formation, allowing the coating to be applied and crosslinked rapidly in situ without requiring weeks of maturation time like traditional linoleum
Solution Approach 2:
The invention utilizes phase transition from liquid coating to crosslinked solid through controlled chemical reaction (crosslinking) at elevated temperatures (50-150°C), transforming the material properties rapidly without requiring long-term oxidative maturation processes
3Quantity of substance
If traditional linoleum synthesis is used, then renewable materials are employed, but mechanical properties and pattern diversity are reduced
Solution Approach 1:
The invention creates composite materials by combining polyols from vegetable oils with isocyanates to form polyurethane systems that integrate the benefits of renewable materials with superior mechanical properties, achieving elasticity, abrasion resistance, and tensile strength exceeding traditional linoleum and PVC
Solution Approach 2:
The invention changes material parameters by controlling the molecular structure of polyols (hydroxyl value, average molecular weight) and the NCO/OH ratio to tune the mechanical properties of the resulting polyurethane, enabling optimization of elasticity, hardness, and durability beyond what traditional linoleum can achieve
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 floor covering with enhanced flexibility, resistance to dirt, abrasion, and UV resistance, while being free from chlorine and phthalates, with a faster manufacturing process and diverse pattern options.
Implementation Method 1
the floor covering according to the invention is obtained by crosslinking, after coating, between a natural polyol such as ricinoleic acid contained in castor oil or glycerol and an isocyanate
Data Source
Figure 1~2
AI summary
The present invention relates to a floor covering comprising a polyurethane obtained by reaction between at least one polyol derived from a renewable plant source and at least one isocyanate, and also to the manufacturing process thereof.