Solid Surface Sheet with Elongated Recycled Filler
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Solution Overview
Problem
Solid surface materials incorporating non-ferrous metal fillers often suffer from weakened internal strength due to poor bonding and air-trapped defects, leading to surface imperfections during finishing.
Innovation Solution
Incorporating elongated shredded cuttings made from thermoset resins like polyester or acrylic, which match the specific weight and polymeric chemistry of the matrix, providing excellent bonding and reducing surface defects by ensuring uniform material strength and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If non-ferrous metal chips and shavings are used as filler in solid surface material, then design variety and texture are improved, but internal strength is weakened due to poor bonding and air-trapped voids
Solution Approach 1:
The patent applies homogeneity by using filler material (ground solid surface material) that has the same polymeric chemistry and physical properties as the base matrix material. This creates a homogeneous composite where filler and matrix are chemically compatible, eliminating bonding issues and air voids that occur with heterogeneous materials like metal chips. The uniform material composition ensures consistent strength throughout the solid surface product.
Solution Approach 2:
The patent creates a composite material system by combining ground solid surface material filler with thermosetting resin matrix. This composite approach allows retention of the original material's desirable properties while adding design variety through controlled incorporation of recycled material containing pigments, fillers, and reinforcing fibers, achieving both aesthetic diversity and structural integrity.
2Adaptability or versatility
If heterogeneous filler materials like metal chips are incorporated, then design options increase, but surface defects increase due to poor bonding and air trapping
Solution Approach 1:
By using filler material with the same polymeric chemistry as the base matrix, the patent ensures homogeneous integration without air voids or poor bonding. This homogeneity eliminates surface defects during sanding and buffing, producing a smooth, defect-free finish while still allowing design variety through pigment and additive incorporation in the ground material.
Solution Approach 2:
The patent controls the particle size distribution and morphology of the ground filler material to optimize surface quality. By adjusting grinding parameters and selecting appropriate feedstock with controlled composition, the patent achieves uniform particle characteristics that pack efficiently and bond seamlessly, preventing air entrapment and surface imperfections during finishing operations.
3Adaptability or versatility
If recycled solid surface particulate material is used as filler, then sustainability and design variety are improved, but bonding strength decreases due to material heterogeneity
Solution Approach 1:
The patent resolves the bonding strength issue by ensuring the recycled filler material maintains the same polymeric chemistry as the base matrix. This chemical homogeneity allows excellent bonding between filler particles and the resin matrix, eliminating the weakness associated with heterogeneous materials. The uniform chemical composition ensures consistent interfacial adhesion throughout the composite structure.
Solution Approach 2:
The patent implements sustainability by recovering and recycling solid surface material that would otherwise be discarded. The ground recycled material is reincorporated as filler, reducing waste and enabling design variety through the pigments and additives contained in the feedstock, while maintaining bonding strength through chemical compatibility.
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 method produces a solid surface sheet with enhanced internal strength and a unique, visually appealing design while minimizing surface defects, maintaining high-quality finishes and durability.
Implementation Method 1
curing a thermosettable resin (such as polyester or acrylic) to a gel state
Data Source
AI summary
A solid surface sheet includes visible, elongated, shredded cuttings uniformly distributed throughout a matrix wherein the cuttings and the matrix have substantially the same specific weight and wherein a majority of the cuttings are substantially elongated. Related methods are also disclosed including shredding a first mix while in a gel state, curing the cuttings, sorting by size, and using as a filler in a base material to form a blend having a unique appearance and high internal strength. The preferred material is polyester or acrylic. The solid surface sheet can be used as a countertop, floor or wall panel, furniture, and in similar applications.