High-Filling Halogen-Free Plastic Board With Recyclable Hot-Pressed Layers
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Solution Overview
Problem
Commercially available halogen-free plastic floors face issues such as high expansion ratios, low surface tension, brittleness, and difficulty in surface processing, and conventional halogen-free materials struggle with large stone powder filling.
Innovation Solution
A halogen-free modified high-filling recyclable plastic board is developed with a substrate layer containing PEAT resin, stone powder, chain extender, white mineral oil, and stearic acid, and a protective layer of PETG film, using a hot press process without glue bonding, allowing for high stone powder filling, improved surface tension, and easy surface processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional halogen-free plastic materials (PE, PP, PET) are used, then the product is environmentally friendly, but they suffer from high expansion ratio, low surface tension, brittleness, and difficulty in surface processing
Solution Approach 1:
The patent uses a composite material system consisting of PEAT resin (polyethylene terephthalate-co-polyethylene adipate) combined with stone powder filler, chain extenders, and lubricants. This composite approach allows the material to simultaneously achieve halogen-free composition, high surface tension for printing, and improved processability without the drawbacks of conventional single materials like PE, PP, or PET
Solution Approach 2:
The patent modifies the chemical composition parameters by using PEAT resin with specific molecular weight (intrinsic viscosity 0.85-0.9 dL/g) and terminal carboxyl group content (6-13 mmol/kg). These parameter changes enable the material to have both high surface tension for printing and reduced brittleness compared to conventional PET
2Stability of the object's composition
If a large amount of stone powder is filled to increase stability, then product stability improves, but expansion ratio increases and surface processing becomes difficult
Solution Approach 1:
The patent optimizes the stone powder particle size distribution and uses chain extenders to modify the polymer matrix properties. The chain extender increases molecular weight and improves the matrix's ability to accommodate filler particles, reducing expansion ratio while maintaining high stone powder content (70-75% by weight) for product stability
Solution Approach 2:
The patent uses chain extenders and lubricants as intermediary substances that mediate between the stone powder filler and the PEAT resin matrix. These intermediaries improve the interfacial bonding and reduce the expansion ratio caused by high filler content, while still allowing 70-75% stone powder for stability
3Object-affected harmful factors
If PEAT resin is used with high stone powder filling, then environmental friendliness and stability improve, but processing difficulty increases due to high melting point and brittleness
Solution Approach 1:
The patent uses chain extenders, white mineral oil, and stearic acid as intermediary substances that facilitate processing. The chain extender modifies the polymer structure to reduce brittleness, while the lubricants (white mineral oil and stearic acid) reduce friction and improve flow during extrusion, making processing easier despite the high stone powder content and PEAT resin properties
Solution Approach 2:
The patent optimizes processing parameters including extrusion temperature (180-220°C), screw speed, and moisture content control. These parameter changes, combined with the addition of lubricants and chain extenders, enable easy processing of the halogen-free PEAT resin composition with high stone powder filling
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 board achieves high thermal stability, compatibility with printed layers, and recyclability, with no halogen elements, and can be recycled as a whole, while maintaining structural integrity and surface processability.
Implementation Method 1
The PEAT resin may function in adhering
Implementation Method 2
The chain extender may serve to increase a length of the chain
Implementation Method 3
The white mineral oil may serve to lubricate and increase plasticization, thus facilitating extrusion
Implementation Method 4
In addition, the stearic acid also provides a lubricating effect
Implementation Method 5
a halogen-free modified high-filling recyclable plastic board is provided in this disclosure, which is formed using a hot press process
Data Source
AI summary
A halogen-free modified high-filling recyclable plastic board is provided in this disclosure, which includes a substrate layer and a printed layer and a protective layer disposed sequentially on the substrate layer from bottom to top. Raw materials of the substrate layer include, by weight in percent, 20 to 25% of PEAT resin, 70 to 75% of stone powder, 0.5 to 0.8% of chain extender, 1 to 2% of white mineral oil, 3 to 6% PE, and 0.4 to 0.8% stearic acid. The plastic board according to the present disclosure is formed using a hot press process, without glue bonding and with good integrity; and the manufactured board is large in surface tension, its surface is easy to be processed and a substrate layer thereof has good compatibility with a printed layer and a protective layer, which can be recycled as a whole.