Covering Panel Substrate with Filler Material to Reduce Curling
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Solution Overview
Problem
Covering panels, such as floor, wall, and ceiling panels, tend to curl due to non-uniform composition and internal stress, leading to installation issues like gaps, impaired adhesion, and reduced mechanical strength, sound insulation, and water resistance.
Innovation Solution
A covering panel with a substrate comprising a synthetic material and a filler material, where the filler material is mixed in an amount from 15 to 75 wt.% based on the total weight, reducing curling and enhancing rigidity, sound absorption, and water resistance, and a process involving mixing, extrusion, and optional lamination to produce these panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a multilayer laminate composition is used for covering panels, then specific functionality can be provided for each layer, but the panels exhibit definite curling tendency due to non-uniform composition and internal stress
Solution Approach 1:
The patent modifies the chemical and physical parameters of the substrate by incorporating specific filler materials (calcium carbonate, talc, silica) in controlled amounts (30-70 wt%). This parameter change alters the thermal expansion characteristics and internal stress distribution of the laminate, thereby reducing curling tendency while preserving the multilayer functional structure.
Solution Approach 2:
The patent creates a composite substrate material combining synthetic polymer with specific filler materials. This composite structure provides both the functional properties of the multilayer laminate and reduced curling, as the filler materials balance the thermal and mechanical properties across different layers.
2Strength
If the amount of filler material in the substrate is increased to reduce curling, then rigidity is improved, but the weight and density of the panel increase
Solution Approach 1:
The patent optimizes the filler material content parameter within the range of 30-70 wt%, finding the optimal balance point where sufficient rigidity is achieved without excessive weight increase. This parameter optimization resolves the contradiction between strength and weight.
3Stability of the object's composition
If the substrate rigidity is increased to reduce curling, then panel stability is improved, but ease of cutting and installation is reduced
Solution Approach 1:
The patent adjusts the substrate composition parameters to achieve optimal rigidity that balances stability with cutability. The controlled addition of filler materials provides enough structural stability while maintaining sufficient flexibility for installation cutting and handling.
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 significantly reduces curling, improves durability, mechanical strength, sound absorption, and water resistance, making the panels more feasible for various applications while being easy to install and transport.
Implementation Method 1
curling is often observed in sheet-type articles which have a non-uniform composition and/or contain zones of internal stress built up during processing
Implementation Method 2
improves durability, mechanical strength, sound absorption
Implementation Method 3
improves durability, mechanical strength, sound absorption, and water resistance
Data Source
AI summary
The present invention provides a covering panel, such as a floor panel, wall panel or ceiling panel, comprising a substrate and optionally a top layer, whereby said substrate comprises a synthetic material and a filler material, whereby said filler material is comprised in an amount from 15 to 75 wt. % based on the total weight of said substrate. In addition, the present invention provides a process of producing such covering panels.