Density Gradient Plastic Carrier for Wall Panels
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Solution Overview
Problem
The production of decorated wall or floor panels can be improved in terms of applicability, particularly for end users, as existing methods do not effectively balance stability and weight, leading to challenges in handling and installation.
Innovation Solution
A carrier material with a thermoplastic matrix and embedded solid particles is designed to have a density gradient along its thickness, decreasing from the lower surface to the upper surface and then increasing, providing targeted properties such as stability and reduced weight, achieved through a specific composition and processing of the carrier material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a carrier material with high density is used to ensure stability, then the panel's stability is improved, but the weight increases making handling and installation difficult
Solution Approach 1:
The patent applies local quality by creating a density gradient within the carrier material where different regions have different densities. The outer regions (near the decorative and substrate surfaces) have higher density to provide stability and strength, while the inner region has lower density to reduce overall weight. This spatial variation in density allows the panel to be both stable and lightweight simultaneously.
Solution Approach 2:
The patent changes the density parameter of the carrier material as a function of position through its thickness. By controlling the density distribution - with maxima at the outer regions and a minimum in the inner region - the material properties are optimized to achieve both high stability at the surfaces and reduced weight in the core, resolving the contradiction between stability and weight.
2Stability of the object's composition
If a dense carrier material is used to improve stability, then the panel becomes more stable, but the handling and installation ease deteriorates due to increased weight
Solution Approach 1:
The carrier material is designed with locally differentiated density properties - high density at the outer regions for stability and low density in the inner region for weight reduction. This local quality differentiation allows the carrier to maintain stability where needed while being lightweight enough for easy handling and installation.
Solution Approach 2:
The patent effectively creates a composite structure within the carrier material itself, combining regions of high density (for stability) and low density (for weight reduction) in a single integrated component. This internal compositing allows the carrier to exhibit both high stability and ease of handling simultaneously.
3Ease of manufacture
If a uniform density carrier material is used, then the production process is simple, but the panel lacks optimized stability and weight properties
Solution Approach 1:
The patent changes the density parameter of the carrier material as a function of position through its thickness. By controlling the density distribution - with maxima at the outer regions and a minimum in the inner region - the material properties are optimized to achieve both high stability at the surfaces and reduced weight in the core, resolving the contradiction between stability and weight.
Solution Approach 2:
The patent applies local quality by creating a density gradient within the carrier material where different regions have different densities. The outer regions (near the decorative and substrate surfaces) have higher density to provide stability and strength, while the inner region has lower density to reduce overall weight. This spatial variation in density allows the panel to be both stable and lightweight simultaneously.
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
This design enhances the panel's stability while reducing weight, improving handling and installation ease, and provides improved moisture resistance and impact sound reduction, while maintaining cost-effectiveness and simplicity in production.
Implementation Method 1
the carrier has a density gradient along its thickness from a lower surface to an upper surface arranged opposite the lower surface such that the density of the carrier material averaged over a defined width or a defined length of at least 5 mm, preferably at least 20 mm, for example of 25 mm, initially decreases from the lower surface to the upper surface and then increases again
Data Source
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AI summary
The present invention relates to a plastic-containing support (10) for a decorated wall panel or floor panel (18), comprising a supporting material (12) including a thermoplastic matrix material, in which a solid material with a particle size less than or equal to 800 µm is embedded, wherein the support (10) has a length (l), a width (b) and a thickness (d), wherein the support (10) has a density gradient along its thickness (d) from a bottom surface (14) to a top surface (16) arranged on the opposite side to the bottom surface (14) in such a manner, that the density of the supporting material (12) averaged over a specified width (b) or a specified length (l) of at least 5mm, preferably at least 20mm, from the bottom surface (14) to the top surface (16) initially declines and then increases again.