Decorative Panel Graphene Wear Layer Hardness
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Solution Overview
Problem
Decorative panels, particularly those with MDF or HDF cores, suffer from hygroscopic issues affecting their durability and are prone to indentation and impact damage due to thin and soft wear layers, leading to dents and permanent deformation under normal use.
Innovation Solution
Incorporating graphene or its derivatives into the decorative top structure of the panels to enhance hardness, impact resistance, and antimicrobial properties, while also improving sound absorption and conductivity, thereby creating a more durable and resistant surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional MDF/HDF core layers are used in decorative panels, then the panels can be manufactured with standard materials and processes, but the panels suffer from hygroscopic issues that reduce their durability and lifetime
Solution Approach 1:
The patent changes the material parameters by replacing traditional hygroscopic MDF/HDF core layers with PVC-based SPC (stone plastic composite) core layers that have superior moisture resistance and dimensional stability, thereby improving reliability without sacrificing manufacturability
Solution Approach 2:
The patent employs composite material structures by combining PVC core layers with decorative substrates and wear layers, creating a multi-layer SPC panel that achieves both moisture resistance and aesthetic functionality while maintaining standard manufacturing processes
2Strength
If the wear layer and core layer are made relatively thin and soft to reduce material usage and cost, then the panels can be manufactured more economically, but the panels cannot withstand high local pressures and easily develop dents, holes, or permanent deformation
Solution Approach 1:
The patent uses composite material structures with multiple functional layers (core layer, decorative layer, wear layer) where each layer contributes specific properties, achieving high impact resistance through material composition rather than simply increasing overall thickness
Solution Approach 2:
The patent applies local quality enhancement by incorporating graphene specifically in the wear layer and decorative top structure where impact resistance is most needed, rather than uniformly thickening the entire panel structure
3Ease of manufacture
If chalk (calcium carbonate) is increased in PVC-based panels to reduce cost price, then the manufacturing cost decreases, but the panels become more prone to indentation and impact damage due to the softening effect of excessive filler
Solution Approach 1:
The patent optimizes the chalk content parameter within specific ranges (5-20 wt%) rather than using excessive amounts, and compensates by incorporating reinforcing materials like graphene to maintain indentation resistance while controlling costs
Solution Approach 2:
The patent creates a composite reinforcement system by combining chalk-filled PVC with graphene and other reinforcing materials, where the composite structure provides both cost effectiveness and mechanical strength against indentation
4Strength
If conventional decorative panels are used without graphene, then the manufacturing process is simpler and more established, but the panels lack sufficient hardness and scratch resistance in the wear layer
Solution Approach 1:
The patent modifies the chemical composition parameters of the wear layer by incorporating graphene at specific concentrations (0.1-5 wt%), which significantly enhances hardness and scratch resistance while maintaining compatibility with existing manufacturing processes
Solution Approach 2:
The patent develops a composite wear layer material combining conventional polymers (PVC, PU) with graphene and other additives, creating a multi-component material system that achieves superior mechanical properties while integrating into existing production lines
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 use of graphene significantly increases the panels' hardness and impact resistance, reduces the risk of bacterial growth, and enhances sound absorption, resulting in a more durable and antimicrobial surface that can withstand high local pressures and maintain appearance over time.
Implementation Method 1
graphene is a single two dimensional layer (2D layer) of carbon atoms, arranged in the form of a honeycomb lattice. This thin, one atom thick lattice is relatively strong, flexible, light-weight
Implementation Method 2
graphene and/or (monolayer) derivatives of graphene display excellent anti-oxidant and scratch-resistant properties. Furthermore, it was found that the graphene and/or derivatives of graphene exhibit(s) excellent antimicrobial properties
Implementation Method 3
graphene also exhibits excellent heat and electricity conducting properties, which beneficial properties may also be used to further improve the decorative panel according to the invention
Implementation Method 4
graphene also exhibits excellent heat and electricity conducting properties
Implementation Method 5
graphene and/or (monolayer) derivatives of graphene display excellent anti-oxidant and scratch-resistant properties. Furthermore, it was found that the graphene and/or derivatives of graphene exhibit(s) excellent antimicrobial properties
Data Source
AI summary
A decorative panel, in particular a floor panel, ceiling panel or wall panel, including a core provided with an upper side and a lower side, a decorative top structure affixed, either directly or indirectly, on said upper side of the core, a first panel edge including a first coupling profile, and a second panel edge including a second coupling profile being designed to engage interlockingly with said first coupling profile of an adjacent panel, both in horizontal and in vertical direction.