TPU-PVC Hot-Melt Composition for Sprayable Non-Skid Flooring Backing
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Solution Overview
Problem
Existing methods for providing non-skid properties to flooring products, such as luxury vinyl tiles, carpets, and rugs, either require soft PVC films that are not sprayable or expensive PVC plastisol that needs heating and curing, lacking a simple and cost-effective solution.
Innovation Solution
A hot-melt composition comprising thermoplastic polyurethane (TPU) and polyvinylchloride (PVC) with a weight ratio of 50/50 to 95/5, which can be easily applied using standard hot melt adhesive tools, providing improved non-skid properties without causing tiles to stick together during shipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If soft PVC film is used to provide non-skid properties, then grip is improved, but sprayability is lost
Solution Approach 1:
The patent changes the material parameters by formulating a hot-melt composition with specific polymer ratios (polyester polyol 30-70 wt%, polyether polyol 10-40 wt%, polyester diol 5-20 wt%, polyether diol 5-20 wt%) and molecular weight ranges that enable both sprayability and softness. This parameter optimization allows the composition to be sprayed while maintaining grip properties.
Solution Approach 2:
The patent uses a composite material system combining multiple polymer types (polyester polyol, polyether polyol, polyester diol, polyether diol) in specific proportions to achieve properties that single materials cannot provide. This composite approach enables both sprayability and softness simultaneously.
2Ease of operation
If PVC plastisol is used to provide non-skid properties, then grip is improved, but processing cost and complexity increase due to heating and curing requirements
Solution Approach 1:
The patent extracts the curing step from the processing sequence by using a hot-melt composition that cures by cooling rather than requiring thermal curing. This eliminates the need for heating and curing equipment, simplifying the process while maintaining grip properties.
Solution Approach 2:
The patent employs a disposable hot-melt composition that is applied and then cures upon cooling, eliminating the need for expensive curing infrastructure. The composition is designed to be single-use and self-curing, reducing overall system cost and complexity.
3Ease of operation
If hot-melt composition is applied to backing, then non-skid properties are improved, but tiles may stick together during shipment in hot climates
Solution Approach 1:
The patent carefully selects polymer molecular weights (polyester polyol 1,000-5,000, polyether polyol 1,000-5,000, polyester diol 500-2,000, polyether diol 500-2,000) and composition ratios to control the melting and curing behavior. This ensures the composition remains stable and non-tacky at shipment temperatures while providing non-skid properties.
Solution Approach 2:
The patent creates local quality differences within the composition by using different polymer types with complementary properties. The polyester components provide structure and stability, while polyether components provide flexibility and temperature resistance, together preventing blocking while maintaining grip.
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 hot-melt composition effectively enhances the friction coefficient of flooring products, preventing blocking and providing reliable anti-skid performance without the need for expensive processing steps, especially in hot climates.
Implementation Method 1
Applying hot-melt composition, wherein the weight ratio of TPU over PVC being in the range of 50/50 to 95/5, to the backside for providing a backing
Implementation Method 2
the hot-melt composition may be applied by melting the hot-melt composition and spraying said molten hot-melt composition to the backside of the floor covering
Implementation Method 3
The used PVC has to be soft in order to provide grip... the plastisol has to provide a softness that will help grip the floor and provide non-skid properties... This low moduli hot-melt composition get deformed easily in shear mode, this helps the composition to grab the substrate and provide anti-skid property
Data Source
Figure 1~3
AI summary
A hot-melt composition is provided which comprises thermoplastic polyurethane (TPU) and polyvinylchloride (PVC), the weight ratio of TPU over PVC is in the range of 50/50 to 95/5.