Decorative products and building products with improved opacity
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Solution Overview
Problem
Existing decorative and building product laminates face challenges in achieving consistent opacity without interfering with visual appeal, and current methods for opacity, such as using TiO2, have limitations in terms of cost, availability, and environmental impact.
Innovation Solution
Incorporating melamine cyanurate (MC) into the laminate structure through various methods, including the papermaking process, non-woven manufacturing, or as a coating, to enhance opacity and improve postformability, potentially substituting or combining with TiO2.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If TiO2 is used to provide opacity in laminates, then opacity is improved, but cost and environmental impact worsen
Solution Approach 1:
The patent changes the chemical composition parameter by replacing TiO2 with melamine cyanurate, which has different optical and chemical properties. This substitution maintains the opacity function while addressing cost and environmental concerns associated with TiO2
Solution Approach 2:
The patent employs melamine cyanurate as a cost-effective alternative to expensive TiO2. The material provides the necessary opacity function at lower cost and with reduced environmental impact, aligning with the principle of using more economical materials when performance requirements are met
2Illumination intensity
If more opacity materials are added to achieve desired visual appearance, then opacity is improved, but manufacturing complexity worsens
Solution Approach 1:
The patent combines the opacity function with the decorative function by incorporating melamine cyanurate into the paper or non-woven layer itself. This integration eliminates the need for separate opacity enhancement steps and reduces manufacturing complexity compared to adding multiple separate material layers
Solution Approach 2:
The melamine cyanurate serves multiple functions simultaneously: it provides opacity, contributes to the visual appearance, and can be integrated into the existing paper or non-woven manufacturing process. This multi-functionality reduces the number of separate manufacturing steps required
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
MC significantly improves opacity and postformability of laminates, offering a cost-effective and environmentally friendly alternative that can reduce the reliance on TiO2, while maintaining or enhancing fire resistance and visual properties.
Implementation Method 1
The light refraction index (LRI) of TiO2 is better than any known substitute, being in the order of 2.7 for rutile and 2.5 for anatase. For comparison the LRIs of alternative materials that are used to provide opacity are in the order of ZnS 2.37, ZnO 2, PCC 1.6, kaolin 1.56, talc 1.57.
Data Source
AI summary
A decorative or building product in which one or more constituents of the product include melamine cyanurate in an amount effective to provide or enhance opacity in the product.