Stone Plastic Floor Eliminating Plasticizers for Temperature Resistance
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Solution Overview
Problem
Conventional stone plastic floors are environmentally hazardous due to plasticizers, have poor contractility, are non-resistant to high temperatures, and have a short lifespan.
Innovation Solution
A high-strength stone plastic floor with a PVC substrate composed of PVC powder, calcium carbonate, stabilizer, flexibilizer, lubricants, and colorant, combined with a color film and wear-resistant surface layer, manufactured through extrusion and calendaring, eliminating plasticizers and enhancing temperature resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional stone plastic floor uses plasticizer to achieve flexibility, then ease of operation is improved, but environmental safety deteriorates due to environmental risks
Solution Approach 1:
The patent removes plasticizer from the formulation entirely, extracting the harmful component while maintaining flexibility through alternative means (PVC powder with specific properties and flexibilizer additives), thus eliminating environmental risks while preserving ease of operation
Solution Approach 2:
The patent changes the chemical composition parameters by replacing plasticizer with a different formulation approach using PVC powder (20-35 wt%) and flexibilizer (1-3 wt%), altering the material's physical and chemical properties to achieve flexibility without harmful substances
2Ease of manufacture
If conventional stone plastic floor uses standard formulation to achieve ease of manufacture, then manufacturing simplicity is improved, but reliability deteriorates due to poor contractility and short lifespan
Solution Approach 1:
The patent optimizes formulation parameters including PVC powder content (20-35 wt%), calcium carbonate (60-70 wt%), stabilizer (1-3 wt%), and flexibilizer (1-3 wt%) to achieve both ease of manufacture and improved reliability with contractility control within 0.06% and extended lifespan
Solution Approach 2:
The patent creates a composite material system combining PVC powder, calcium carbonate, stabilizer, flexibilizer, lubricant, and colorant in specific proportions, where the synergistic interaction of components achieves both manufacturing ease and enhanced reliability through improved contractility and durability
3Ease of manufacture
If conventional stone plastic floor uses standard material composition to achieve ease of manufacture, then production simplicity is improved, but temperature resistance deteriorates causing softening under high temperature
Solution Approach 1:
The patent modifies the material composition parameters by incorporating stabilizer (1-3 wt%) and specific PVC powder properties that elevate the thermal stability threshold, enabling the floor to maintain structural integrity at high temperatures while preserving production simplicity through a straightforward formulation process
Solution Approach 2:
The patent develops a composite formulation where stabilizer and PVC powder work synergistically to provide high-temperature resistance, preventing softening under thermal exposure while maintaining ease of manufacture through a unified processing approach
4Ease of operation
If conventional stone plastic floor uses plasticizer-based formulation to achieve flexibility, then ease of operation is improved, but lifespan deteriorates due to short service life
Solution Approach 1:
The patent eliminates plasticizer from the formulation, removing the source of degradation that limited lifespan, while maintaining flexibility through alternative components (PVC powder and flexibilizer), thereby extending service life without sacrificing operational flexibility
Solution Approach 2:
The patent changes the chemical composition parameters by replacing plasticizer with a more stable formulation system, altering the degradation kinetics and extending the duration of action (lifespan) while preserving the flexibility needed for ease of operation
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 results in a floor with improved contractility, high temperature resistance, extended lifespan, and the ability to integrate different surface layers, reducing environmental risks and enhancing durability.
Implementation Method 1
mixing and stirring the above materials
Implementation Method 2
in the extrusion step, the temperature is 187-210° C.
Data Source
AI summary
The invention provides a high strength stone plastic floor and manufacturing method thereof. The stone plastic floor comprises a PVC substrate and a surface layer on a surface of the PVC substrate. Compositions of PVC substrate comprise: PVC powder from 20 to 35 weight percent, calcium carbonate from 60 to 70 weight percent, stabilizer from 1 to 3 weight percent, flexibilizer from 1 to 3 weight percent, lubricants from 0.4 to 1 weight percent, and colorant from 0.4 to 1 weight percent. The high strength stone plastic floor does not contain plasticizer so environmental risks are completely avoided. The contractility is good. The high strength stone plastic floor is resistant to high temperature and direct sunlight. Compared with conventional stone plastic floor, lifespan of the present invention is prolonged. The PVC substrate of the floor can be combined with different layers and can integrate different advantages of other floors.