Elastomer Powder-Modified Thermoplastic Decorative Panel
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Solution Overview
Problem
Existing decorative panels face challenges with plastic carriers derived from mineral oils, which are costly and ecologically critical, particularly due to the use of phthalates as plasticizers in PVC materials, limiting their application in wet rooms and outdoors.
Innovation Solution
A decorative panel with a plate-shaped carrier made from a thermoplastic composition modified with fine-grained, cross-linked elastomer powder, combining a thermoplastic matrix material with powdery elastomer material, enhancing sound insulation and moisture resistance, and using recycled elastomer materials to reduce environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional PVC-based plastic carriers are used, then the panels are cost-effective and easy to manufacture, but they are ecologically critical due to phthalate plasticizers and hazardous substances
Solution Approach 1:
The patent changes the chemical composition parameters of the plastic carrier by replacing PVC with thermoplastic compositions modified with elastomer powder (2-20 wt%), eliminating phthalate plasticizers and hazardous substances while maintaining manufacturability
Solution Approach 2:
The patent creates a composite material system combining thermoplastic matrix material with elastomer powder particles, achieving both ecological sustainability and ease of manufacture without hazardous additives
2Ease of manufacture
If mineral oil-based plastic materials are used, then the panels are cost-effective, but they are costly and ecologically critical
Solution Approach 1:
The patent changes the material source parameters from mineral oil-based plastics to bio-based or recycled thermoplastic materials, reducing ecological impact while maintaining cost-effectiveness through sustainable sourcing
Solution Approach 2:
The patent incorporates recycled elastomer materials (2-20 wt%) into the thermoplastic composition, recovering valuable materials from waste streams and reducing the need for virgin mineral oil-based plastics
3Ease of manufacture
If PVC with phthalate plasticizers is used, then the panels are easy to produce, but they are ecologically critical and hazardous
Solution Approach 1:
The patent extracts and eliminates phthalate plasticizers and hazardous substances from the material composition, replacing them with safe thermoplastic-elastomer compositions that maintain ease of production without ecological harm
Solution Approach 2:
The patent converts the harmful effect of needing plasticizers for PVC flexibility into a benefit by using elastomer powder-modified thermoplastics that provide flexibility and elasticity without requiring hazardous phthalate additives
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 provides a water-resistant, elastic, and cost-effective decorative panel with high temperature resistance, eliminating the need for plasticizers and hazardous substances, offering an eco-friendly alternative to traditional PVC-based panels.
Implementation Method 1
a thermoplastic composition modified with an elastomer powder by means of melt blending, wherein the thermoplastic composition includes at least one thermoplastic matrix material and at least one fine-grained, cross-linked and powdery elastomer material incorporated into the matrix material
Implementation Method 2
The solution provides a water-resistant, elastic, and cost-effective decorative panel with high temperature resistance, eliminating the need for plasticizers and hazardous substances
Implementation Method 3
combining a thermoplastic matrix material with powdery elastomer material, enhancing sound insulation and moisture resistance
Data Source
AI summary
A decorative panel comprising at least a plate-shaped carrier and a decorative layer disposed thereon and which is characterized in that the plate-shaped carrier comprises at least partially a thermoplastic composition modified with an elastomer powder by means of melt blending, wherein the thermoplastic composition includes at least one thermoplastic matrix material and at least one fine-grained, cross-linked and powdery elastomer material incorporated into the matrix material. A method for producing the foregoing decorative panel comprising applying a decorative layer to the plate-shaped carrier.