Composite Panel with Modified PVC Substrate and Crosslinking Layer
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Solution Overview
Problem
Traditional solid wood floors are environmentally destructive and expensive, while traditional hard PVC panels are hard, monotonous, and lack comfort and visual appeal, making them unsuitable for high-end applications.
Innovation Solution
A composite panel with a substrate layer composed of PVC resin, stone powder, and a molding optimizing agent, which can include additives like stabilizers and plasticizers, combined with functional layers such as wear-resistant or veneer layers, and a crosslinking layer for enhanced bonding, and a UV coating for improved appearance and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional hard PVC is used as panel material, then flame retardancy and water resistance are improved, but hardness and poor touch comfort worsen
Solution Approach 1:
The patent applies composite materials by combining PVC resin with rubber particles and other additives to create a modified PVC composition. This composite structure allows the material to maintain flame retardancy while gaining flexibility and touch comfort through the rubber phase dispersion, resolving the contradiction between hardness and comfort.
Solution Approach 2:
The patent changes the chemical composition parameters of PVC by incorporating rubber particles, plasticizers, and other modifiers. This parameter modification transforms the material properties, reducing excessive hardness while preserving flame retardancy and water resistance, thus improving touch comfort without sacrificing reliability.
2Reliability
If traditional hard PVC is used as panel material, then flame retardancy and water resistance are improved, but color monotony and poor visual effect worsen
Solution Approach 1:
The patent uses composite materials by integrating PVC resin with rubber particles, colorants, and surface modifiers. This composite approach enables diverse color formulations and surface finishes while maintaining the inherent flame retardancy of PVC, thereby improving visual effect without compromising reliability.
Solution Approach 2:
The patent modifies the compositional parameters of PVC by adding colorants, pigments, and surface treatments. These parameter changes enable rich color variations and enhanced visual appeal while preserving the flame retardant properties, resolving the contradiction between reliability and visual effect.
3Strength
If adherence enhancement treatment is applied to PVC panels, then bonding strength is improved, but processing complexity worsens
Solution Approach 1:
The patent applies preliminary action by incorporating adhesion promoters and surface modifiers directly into the PVC composition during manufacturing. This preliminary incorporation ensures good bonding strength is achieved inherently, eliminating the need for separate adherence enhancement treatments and thereby reducing processing complexity.
Solution Approach 2:
The patent merges the adhesion enhancement function with the base PVC material by integrating adhesion promoters into the formulation. This merging combines multiple functions (structural integrity and bonding capability) into a single material system, simplifying the overall processing procedure while maintaining strong bonding strength.
Data Source
AI summary
The present invention provides a composite panel, containing a substrate layer and at least one functional layer disposed above and/or below the substrate layer. The composite panel of present invention is environmentally friendly with zero formaldehyde, elastic and comfortable to touch, and has good appearance. The composite panel of the present invention may subject to surface treatments in accordance with actual needs to provide better functionality and practicality.