SBIR Phase I: An Environmentally Sustainable Approach to PVC-Free Flooring

这个小企业创新第一阶段项目建议开发技术和产品，以消除聚氯乙烯（PVC）在其最大的使用量之一，地板材料中的使用。Interfacial Solutions最近证明，通过使用创新的材料复合和新颖的连续板材加工技术，大量低成本的塑料废物流可以转化为有价值的地板板材产品。大量低成本的塑料废物流包括从废物流中回收的聚烯烃，这些废物流通常没有什么价值，通常被丢弃到垃圾填埋场。为了有效地均匀化废物流中的可变性并去除污染物，已经开发出一种塑料化合物，这种化合物可以转化为地板板材材料，并有可能成为地板市场上PVC的替代品。还确定了一种连续创建片状材料的新工艺。为了完成这项技术的开发并颠覆现有的产品，需要推进新技术，以改善地板结构中各层之间的粘合剂粘合，设计阻燃性能以满足行业规范，并展示具有当前产品耐久性和性能的成本效益的工艺。该项目的更广泛的影响/商业潜力是去除地板产品中的PVC，并将大量塑料废物蒸汽转化为有用的产品。如今，被利用的废物流大部分被丢弃到垃圾填埋场。从环境和健康风险的角度来看，PVC是有问题的。在世界范围内，政府机构和非政府组织正在寻找PVC替代品。此外，PVC不易回收，因此一旦进入产品，就会成为一个重要的废物来源。生命的终结，由于其释放二恶英的倾向，在处置过程中也会产生重大的健康和环境后果。通过开发这项新技术，将低成本的塑料废物转化为具有与PVC相当或超过PVC性能的复合材料，每年有机会去除约20亿平方米的PVC地板。该方案开发的技术平台也可以用于替代户外标牌、船用胶合板和混凝土形式中使用的化学处理胶合板。

This Small Business Innovation Phase I project proposes to develop technology and products that will eliminate the use of polyvinylchloride (PVC) in one of its largest volume uses, flooring materials. Interfacial Solutions has recently demonstrated that a high volume low cost plastic waste stream can be converted into a valuable flooring sheet product by using innovative material compounding and novel continuous sheet processing techniques. The high volume low cost plastic waste stream comprises polyolefins that have been reclaimed from waste streams typically having little value and usually discarded to landfills. Innovations to effectively homogenize the variability in the waste stream and remove contaminants have been developed to create a plastic compound that can be converted into flooring sheet materials and potentially useful as a replacement to PVC in the flooring market. A novel process to continuously create sheet materials has also been determined. To complete the development of this technology and disrupt incumbent products, the new technology needs to be advanced to improve the adhesive bonding between layers in the flooring construction, engineer flame retardant properties to meet industry specifications, and demonstrate a cost effective process with the durability and performance of current products. The broader impact/commercial potential of this project is the removal of PVC from flooring products and the conversion of a significant plastic waste steam into useful products. The waste stream being utilized is largely scrapped into landfills today. From an environmental and health risk standpoint, PVC is problematic. Worldwide, government agencies and NGOs are seeking alternatives for PVC replacement. Furthermore, PVC cannot be easily recycled, and therefore a significant source of waste once it has reached a products? end of life, also with significant health and environmental consequences during disposal due to its propensity to liberate dioxins. By developing this new technology to convert a low cost plastic waste stream into composite materials with properties comparable or exceeding PVC, an opportunity exists to remove some 2 billion square meters of PVC flooring per year. The technology platform developed by this proposal can also be of utility in replacing chemically treated plywood used in outdoor signage, marine plywood and concrete forms.