Stone-Plastic Floor Without Plasticizers for High Temperature Resistance
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Solution Overview
Problem
Existing stone-plastic floors have issues with environmental safety due to plasticizing agents, low hardness, large expansion and contraction coefficients, poor shrinkage performance, inability to tolerate high temperatures, short service life, and complex production processes leading to low production efficiency.
Innovation Solution
A stone-plastic floor composition without plasticizing, toughening, or foaming agents, using a resin substrate with specific ratios of resin, calcium carbonate, and auxiliary agents, and a method involving heating, stirring, and thermal molding with calendering to achieve high strength, hardness, and stability, enabling continuous production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plasticizing agents are added to improve processability, then the material becomes easier to mold, but environmental safety deteriorates and hardness decreases
Solution Approach 1:
The patent removes plasticizing agents, foaming agents, and other harmful additives from the resin composition entirely. The invention achieves processability without these substances by using a carefully selected combination of resins (PVC, PP, PE, PS, ABS, PC, PMMA, PMV) and calcium carbonate filler, eliminating the need for plasticizing agents while maintaining environmental safety and improving hardness.
2Ease of manufacture
If traditional resin compositions are used to achieve flexibility, then processability improves, but hardness and stability deteriorate
Solution Approach 1:
The patent uses a composite resin system combining multiple resin types (PVC, PP, PE, PS, ABS, PC, PMMA, PMV) with calcium carbonate filler. This composite approach provides both flexibility for processing and high hardness in the final product, resolving the contradiction between ease of manufacture and strength. The specific formulation contains no plasticizing agents yet achieves desirable processing characteristics.
3Volume of stationary object
If foaming agents are added to create cellular structure, then volume expansion is achieved, but high temperature resistance deteriorates and stability decreases
Solution Approach 1:
The patent completely eliminates foaming agents from the composition. The invention achieves volume control and structural integrity through the resin-filler composite system without cellular structure, thereby maintaining high temperature resistance and stability. The floor can be installed in high-temperature environments such as areas with underfloor heating without softening or deforming.
4Manufacturing precision
If stagewise processing is used to ensure quality, then manufacturing precision improves, but productivity deteriorates
Solution Approach 1:
The patent combines multiple processing steps into a single continuous extrusion process. The resin composition is mixed and extruded in one operation, eliminating the need for separate stages of mixing, molding, and finishing. This integration maintains manufacturing precision while dramatically improving productivity and enabling continuous production.
5Reliability
If complex multi-step processing is implemented to achieve desired properties, then product performance improves, but device complexity increases
Solution Approach 1:
The patent performs preliminary formulation of the resin composition with all necessary components (resins and calcium carbonate) in the correct proportions before extrusion. This pre-formulation ensures that the desired product properties are achieved through the composition design itself rather than through complex processing steps, thereby reducing device complexity while maintaining product 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 results in a stone-plastic floor with improved strength, hardness, and stability, capable of withstanding high temperatures and direct sunshine, with a longer service life and increased production efficiency, while avoiding environmental hazards and complex production steps.
Implementation Method 1
heating, stirring and mixing raw materials uniformly in proportion, and then delivering resulting mixed materials to a mold for plastic molding and thermal insulation
Implementation Method 2
plastic molding and thermal insulation
Implementation Method 3
heating, stirring and mixing raw materials uniformly in proportion
Implementation Method 4
attaching a resulting profile after mold release with a surface layer and then performing thermal calendering attachment
Data Source
AI summary
Disclosed are a stone-plastic floor and a method of preparing the same. The resin substrate of the stone-plastic floor of the present disclosure is prepared by using raw materials with specific components and amounts, without using any plasticizing agent, toughening agent and foaming agent and without environmental hidden dangers. The resulting stone-plastic floor has high strength, high hardness, excellent shrinkage performance and no environmental hidden dangers, and can tolerate direct sunshine, and has good stability and long service life for use safety. The method of preparing the stone-plastic floor of the present disclosure has simple processes, enabling online continuous production with high production efficiency.