Decorative Panel With Gradient Crystallinity Core
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing decorative panels made from halogenated amorphous thermoplastics like PVC face environmental and health concerns due to disposal issues, toxic emissions during processing, and challenges in recycling. Additionally, semi-crystalline thermoplastics used as alternatives can develop residual stresses causing warping and brittleness, making them unsuitable for decorative applications.
Innovation Solution
A decorative panel comprising a core layer with a structural core component and a balancing core component, where the structural core component includes a mineral filler and a first polymeric composition, and the balancing core component comprises a second polymeric composition. This combination achieves a semi-rigid panel that is dimensionally stable, free of halogens and plasticizers, and suitable for various installations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If semi-crystalline thermoplastics are used as alternative to PVC, then environmental and health concerns are reduced, but residual stresses cause warping and brittleness
Solution Approach 1:
The patent applies local quality by creating a core layer with non-uniform crystallinity distribution, where the surface region has higher crystallinity (30-60%) than the interior region (10-40%). This gradient structure allows the surface to provide dimensional stability and resistance to warping, while the interior maintains flexibility and reduces brittleness, thus resolving the contradiction between environmental safety and dimensional stability.
Solution Approach 2:
The patent utilizes parameter changes by controlling the crystallinity degree as a gradient from surface to interior. The surface region is engineered with 30-60% crystallinity to prevent warping, while the interior maintains 10-40% crystallinity to reduce brittleness. This parameter gradient approach allows the material to simultaneously achieve dimensional stability and reduced brittleness, resolving the technical contradiction.
2Object-affected harmful factors
If semi-crystalline thermoplastics are used, then environmental concerns are reduced, but brittleness increases
Solution Approach 1:
The patent applies local quality by creating a core layer with non-uniform crystallinity distribution, where the surface region has higher crystallinity (30-60%) than the interior region (10-40%). This gradient structure allows the surface to provide dimensional stability and resistance to warping, while the interior maintains flexibility and reduces brittleness, thus resolving the contradiction between environmental safety and dimensional stability.
Solution Approach 2:
The patent utilizes parameter changes by controlling the crystallinity degree as a gradient from surface to interior. The surface region is engineered with 30-60% crystallinity to prevent warping, while the interior maintains 10-40% crystallinity to reduce brittleness. This parameter gradient approach allows the material to simultaneously achieve dimensional stability and reduced brittleness, resolving the technical contradiction.
3Reliability
If additional balancing layers are laminated to the core layer, then dimensional stability is improved, but production complexity and cost increase
Solution Approach 1:
The patent applies merging by integrating the balancing layer function directly into the core layer structure. The core layer itself is designed with a gradient crystallinity structure that provides inherent dimensional stability, eliminating the need for separate balancing layers. This combines the core layer and balancing layer functions into a single component, reducing production complexity while maintaining dimensional stability.
Solution Approach 2:
The patent applies universality by designing the core layer to serve multiple functions simultaneously: it provides structural support, dimensional stability, and warping resistance through its gradient crystallinity structure. This multi-functional core layer eliminates the need for additional specialized layers, simplifying the overall panel construction and production process.
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 panel achieves enhanced thermal stability, mechanical properties, and dimensional stability, allowing it to retain structural integrity and functionality at higher temperatures. The integrated balancing layer within the core layer eliminates the need for additional production steps, such as laminating balancing layers, resulting in a more stable and cost-effective product.
Implementation Method 1
at least one structural core component has a first hardness and/or crystallinity, and wherein at least one balancing core component has a second hardness and/or crystallinity. The second hardness and/or crystallinity is preferably 3-35% higher than a first hardness and/or crystallinity
Data Source
AI summary
The invention relates to a decorative panel, in particular a floor, ceiling, building or wall panel, and a process and extrusion line for producing such decorative panel. The panel comprises at least one core layer and at least one decorative top layer, wherein at least one core layer comprises at least one structural core component and at least one balancing core component, wherein at least one structural core component comprises at least one mineral filler and at least one first polymeric composition and wherein at least one balancing core component comprises at least one second polymeric composition.