Composite Sheet with Heat-Resistant Waste Chips
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Solution Overview
Problem
Home appliances require materials that enhance both aesthetics and eco-friendliness while maintaining mechanical properties such as surface hardness, strength, and thermal resistance.
Innovation Solution
A composite sheet is developed using a thermoplastic matrix and chips formed from highly heat-resistant waste materials, such as artificial marble or super engineering plastics, which are exposed on the surface through etching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If waste materials are used to manufacture composite sheets, then eco-friendliness is improved, but mechanical properties such as surface hardness and strength may deteriorate
Solution Approach 1:
The patent creates a composite sheet by combining a thermoplastic matrix with heat-resistant waste material chips (such as PEEK, PTFE, PAI, PI, or artificial marble). This composite structure allows the material to inherit the eco-friendliness of recycled waste materials while gaining improved mechanical properties from the synergistic combination of matrix and chips, particularly enhanced surface hardness and strength.
Solution Approach 2:
The patent specifies that the waste material chips must have a melting point of 200°C or higher, which is a critical parameter change that ensures the heat-resistant waste materials can maintain structural integrity and provide mechanical strength in the composite sheet, resolving the contradiction between using waste materials and maintaining mechanical properties.
2Temperature
If chips with large size are used, then heat resistance is improved, but manufacturing precision and surface quality may deteriorate
Solution Approach 1:
The patent defines a specific size range for the waste material chips (1 mm to 3 cm in average size) and requires a melting point of 200°C or higher. This parameter optimization ensures that chips are large enough to provide heat resistance but small enough to maintain surface quality and manufacturing precision, resolving the contradiction between heat resistance and surface quality.
3Shape
If the surface is etched to expose chips, then aesthetics are improved, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes the natural colors and textures of the exposed waste material chips (such as artificial marble or engineered plastics) on the sheet surface to create aesthetic patterns. The etching process exposes these chips to create a visually appealing surface with varied textures and colors, improving aesthetics while the process remains integrated into the existing manufacturing workflow.
4Ease of manufacture
If thermoplastic matrix is used, then ease of manufacture is improved, but heat resistance may deteriorate
Solution Approach 1:
The patent combines a thermoplastic matrix with heat-resistant waste material chips having melting points of 200°C or higher. The thermoplastic matrix provides ease of manufacture through conventional processing methods, while the heat-resistant chips embedded within the matrix provide the necessary thermal stability, resolving the contradiction between ease of manufacture and heat resistance.
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 composite sheet improves mechanical properties, enhances aesthetics, and increases eco-friendliness, while providing improved heat resistance and safety in the event of a fire.
Implementation Method 1
The matrix may be a thermoplastic material. The base resin may be a thermoplastic material.
Implementation Method 2
After extruding a mixture containing a base resin constituting the matrix and the chip into a sheet shape, the surface of the extruded sheet may be etched so that at least a portion of the plurality of the chips is exposed.
Data Source
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AI summary
A composite sheet, a method for manufacturing the composite sheet, and a home appliance including the composite sheet are provided. A composite sheet according to an embodiment includes a matrix including a base resin which contains a thermoplastic material; and chips by pulverizing waste materials having irregular shapes and coupled by the matrix and the chips partially exposed to an outer surface of the composite sheet, wherein a range of sizes of the chips has from 1mm to 3cm and a temperature of melting point of the chips has 200°C over.