Foamed Composite Board with Solid Plastic Layer
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Solution Overview
Problem
Composite formed boards used in outdoor construction elements face issues of brittleness, heavy weight, and manufacturing inefficiencies, such as non-uniform profiles and increased specific gravity, which affect their usability and safety.
Innovation Solution
A composite formed board is created by bonding a foamed mix of plastic and organic material with a fibrous structure to a solid plastic layer, where the foamed mix has a lower density, and the solid plastic layer is bonded permanently with a rubber-polyurethane composite, reducing the overall specific gravity and maintaining hardness and elasticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the solid layer is increased to improve hardness, then the hardness is improved, but the specific gravity increases dramatically
Solution Approach 1:
The invention applies different material densities to different layers: a dense solid plastic layer (3-10mm) for hardness at the top, and a lightweight foamed composite layer (10-30mm) for weight reduction at the bottom. This local differentiation allows the board to achieve required surface hardness without increasing overall specific gravity.
Solution Approach 2:
The invention uses a composite structure combining solid plastic with foamed organic-material composite. The foamed layer contains air pockets that significantly reduce density while maintaining structural integrity, thus reducing specific gravity while preserving the hardness provided by the solid plastic top layer.
2Productivity
If extrusion method is used to create construction elements, then production efficiency is improved, but non-uniform profile and manufacturing defects occur
Solution Approach 1:
The board is divided into two separately manufactured layers that are subsequently bonded: a solid plastic top layer and a foamed organic-material bottom layer. This segmentation allows each layer to be optimized independently for its specific function, avoiding the profile uniformity issues that would affect an entirely extruded monolithic structure.
Solution Approach 2:
The invention merges two separately manufactured layers (solid plastic layer and foamed composite layer) through bonding. This combining approach preserves the production efficiency of separate manufacturing while eliminating the profile defects associated with single-step extrusion of complex multi-density structures.
3Strength
If permanent bond is applied in the joint area, then connection strength is improved, but flexibility and error tolerance are reduced
Solution Approach 1:
The bonding system applies different bond characteristics to different areas: permanent chemical bonding in the joint region for structural strength, and impermanent mechanical bonding in the letter-shape base area for flexibility and error tolerance. This local differentiation allows the same structure to provide both strong connection and adaptability.
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 reduces the mechanical loads and weight of the composite formed boards, making them easier to transport and install, while preserving their structural advantages and user-friendly characteristics.
Implementation Method 1
a composite made of plastic and organic material with a fibrous structure is a foamed mix with a density lower by at least 10%, preferably by at least 20%, than the density of a solid organic-plastic composite made of the same components
Implementation Method 2
made of rubber aggregate combined with polyurethane resin to the form of a homogeneous rubber-polyurethane composite
Implementation Method 3
the solid plastic layer is bonded permanently with a rubber-polyurethane composite
Data Source
AI summary
Composite formed boards made of plastic and organic material with a fibrous structure are described. The composite is a foamed mix having a density lower by at least 10% and preferably 20%, than the density of a solid organic-plastic composite made of the same components. The foamed mix is bonded permanently and inseparably with a solid plastic layer, at least from a side opposite to a homogeneous rubber-polyurethane composite. The thickness of the solid plastic layer is smaller than that of the organic-plastic layer (preferably at least five times and most preferably at least fifteen times) and that of the rubber-polyurethane layer (preferably at least fifteen times and most preferably at least twenty-five times). The solid plastic layer may have a grooved structure or an impressed structure with a concavity directed inwardly. The solid plastic layer is preferably bonded with the organic-plastic layer by a co-extrusion joint.