Magnesium Oxide Floor Panel with Whisker-Phase Crystals
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Solution Overview
Problem
Traditional materials used in flooring, such as PVC and HDF, lack sufficient bending strength, impact resistance, and internal cohesion, making them unsuitable for use as floor panels, while mineral materials like magnesium oxide-based panels require improvements in these properties to be viable alternatives.
Innovation Solution
A composite mineral panel with a core layer comprising a magnesium oxide composition that includes magnesium oxide and magnesium salt, featuring a magnesium crystal structure with over 50% whisker-phase crystals, enhanced by the addition of compounds with hydroxyl groups, which improves internal cohesion and impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional materials (PVC, HDF) are used for flooring, then manufacturing and installation are easier, but bending strength, impact resistance, and internal cohesion are insufficient
Solution Approach 1:
The patent uses a composite mineral material consisting of magnesium oxide particles bound together with a binder, creating a panel that achieves superior bending strength and impact resistance compared to traditional homogeneous materials like PVC or HDF, while maintaining manufacturability through a standardized production process
2Reliability
If mineral materials (magnesium oxide) are used for flooring, then environmental impact is reduced and dimensional stability is improved, but bending strength, impact resistance, and internal cohesion need improvement
Solution Approach 1:
The patent modifies the physical and chemical parameters of the magnesium oxide panel by adjusting the particle size distribution, binder composition, and curing conditions to enhance impact resistance and internal cohesion while preserving the inherent dimensional stability and environmental benefits of mineral materials
Solution Approach 2:
By creating a composite structure combining magnesium oxide particles with a binder system, the patent achieves both the dimensional stability of mineral materials and the impact resistance typically associated with more traditional flooring materials
3Object-generated harmful factors
If mineral materials are used for flooring, then environmental impact is reduced, but surface adhesion and internal cohesion are insufficient
Solution Approach 1:
The patent creates a composite mineral panel where magnesium oxide particles are bound together through a binder system, achieving improved internal cohesion and surface adhesion while maintaining the environmental benefits of using natural mineral materials alternative to PVC or HDF
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 exhibits improved bending strength, impact resistance, and internal cohesion, making it suitable for decorative residential and commercial flooring applications with enhanced durability and stability.
Implementation Method 1
at least one core layer comprises a magnesium oxide composition comprising at least a magnesium oxide and a magnesium salt, wherein said magnesium oxide composition comprises a magnesium crystal structure. The magnesium crystal structure preferably comprises at least 50% by weight of at least one whisker-phase magnesium crystal structure.
Data Source
AI summary
Provided is a panel, in particular a floor panel, suitable for forming a floor covering. The panel has a substantially planar top side, a substantially planar bottom side, at least four substantially linear side edges each including at least one pair of opposite side edges, preferably provided with locking means.