Elastic Polyurethane Panel With Mineral Aggregates For Dimensional Stability
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Solution Overview
Problem
Existing panels for flooring and wall coverings face challenges in achieving a balance between flexibility, dimensional stability, and weight, with conventional materials often being either too rigid or prone to warping, and lacking in moisture resistance and sound insulation.
Innovation Solution
A multi-layer panel structure featuring an elastic polyurethane base layer with embedded mineral aggregates, a decorative layer made from cellulose-based materials impregnated with synthetic resins, and a thermoplastic adhesive layer, which allows for flexible installation and high indentation resistance while maintaining dimensional stability and waterproof properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional rigid materials are used for panels, then dimensional stability is improved, but flexibility and resistance to breaking deteriorate
Solution Approach 1:
The patent employs a composite structure consisting of a rigid board layer combined with a flexible polymer foam layer. This multi-material construction allows the panel to simultaneously achieve dimensional stability from the rigid board and flexibility from the elastic foam, resolving the contradiction between rigidity and flexibility.
Solution Approach 2:
Different regions of the panel have different material properties: the board layer provides rigidity and dimensional stability where needed, while the polymer foam layer provides flexibility and shock absorption in other regions. This spatial differentiation of material qualities allows the panel to satisfy both contradictory requirements.
2Object-affected harmful factors
If heavy materials are used to increase weight, then sound insulation and stability are improved, but ease of handling and installation deteriorate
Solution Approach 1:
The patent combines heavy rigid board material with lighter polymer foam material to create a composite panel. This allows the panel to achieve good sound insulation and stability from the board layer while maintaining lighter overall weight and better handleability from the foam layer, resolving the contradiction between weight and ease of operation.
3Ease of operation
If porous materials are used for flexibility, then ease of installation is improved, but moisture resistance deteriorates
Solution Approach 1:
The patent uses a non-porous rigid board layer combined with a closed-cell polymer foam layer. The closed-cell structure of the foam provides flexibility and ease of installation while maintaining excellent moisture resistance, as the closed cells prevent water penetration. This composite approach resolves the contradiction between porosity and moisture 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 panel achieves flexibility without breaking, excellent indentation resistance, and dimensional stability, with minimal water absorption and no swelling, making it suitable for underfloor heating and providing a quiet, even surface.
Implementation Method 1
The base layer consists entirely or predominantly of an elastically adjusted polyurethane
Implementation Method 2
The top layer is pressed to the base layer via an adhesive layer to form the multi-layer structure
Data Source
AI summary
A panel whose edge surfaces are designed to be connected to other panels in order to cover an area of a room, wherein the panel has a top surface, a bottom surface and at least four edge surfaces, wherein couplings for connecting to adjacent panels are formed on at least one pair of opposite edge surfaces, wherein the panel has a multilayer structure with an elastic base layer on which the couplings are formed at least partially, wherein the base layer consists entirely or predominantly of an elastically modified polyurethane and with a less elastic top layer above the base layer, wherein the top layer is pressed onto the base layer via an adhesive layer to form the multilayer structure, wherein the base layer contains aggregates of a mineral basis or of their synthetic equivalents, such that the density of the base layer is greater than 1.It is set to 8 g/cm3.