Decorated Panel Carrier Material Composite Design
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Solution Overview
Problem
Existing decorated wall and floor panels lack improved elastic properties, which affects their dimensional stability and manufacturability, particularly in response to moisture and temperature changes.
Innovation Solution
A carrier material comprising a matrix material and a solid material, where the matrix material constitutes 25-55 wt.% and the solid material constitutes 45-75 wt.%, primarily composed of layered silicate powders and a plastic composition of homopolymer and copolymers, enhancing mechanical and elastic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional carrier materials are used for decorated panels, then manufacturing is simple and cost-effective, but elastic properties and dimensional stability are insufficient
Solution Approach 1:
The patent applies composite materials by combining mineral-based solid composition (45-75 wt.%, particularly 55-65 wt.%) with matrix material (25-55 wt.%, particularly 35-45 wt.%) to create a WPC carrier material. This composite structure integrates the dimensional stability of mineral fillers with the binding properties of the matrix, resolving the contradiction between stability and complexity by creating a functionally optimized composite system.
Solution Approach 2:
The patent applies parameter changes by precisely controlling the weight ratio parameters of matrix material (25-55 wt.%) and solid material (45-75 wt.%) to optimize elastic properties. By adjusting these compositional parameters within specific ranges, the invention achieves improved elastic properties and dimensional stability while managing material complexity through quantified composition control.
2Strength
If mineral filler content is increased to improve elastic properties, then panel stability improves, but manufacturability and mass flow rate may deteriorate
Solution Approach 1:
The patent applies parameter changes by optimizing the solid material content within the range of 45-75 wt.%, particularly 55-65 wt.%, to achieve improved flexural strength while maintaining manufacturability. This parameter optimization ensures that elastic properties are enhanced without compromising the mass flow rate and processing characteristics of the carrier material.
Solution Approach 2:
The patent applies local quality by differentiating the functional roles of matrix material and solid material within the composite. The matrix material provides binding and processability, while the solid material provides structural strength and elastic properties. This functional differentiation allows each component to be optimized for its specific role, resolving the contradiction between strength and manufacturability.
Data Source
AI summary
A carrier material for producing a decorated wall or floor panel, as well as the corresponding wall or floor panel, may comprise a matrix material and a solid material. The matrix material is present from ≥25 wt.-% to ≤55 wt.-% and the solid material is present from ≥45 wt.-% to ≤75 wt.-% of the carrier material. The matrix material and the solid material together may be present in an amount of ≥95 wt.-% of the carrier material. The solid material is formed to at least 50 wt.-% of a solid composition consisting of at least a first layered silicate powder and a second layered silicate powder. The matrix material is formed to at least 50 wt.-% by a plastic composition consisting of a homopolymer and at least a first copolymer and a second copolymer.