Thermoplastic Board Layers From Recycled Material With Ratio Control
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Solution Overview
Problem
Existing recycling processes for thermoplastic-based panels face challenges in maintaining precise material ratios, leading to compromised panel quality, and there is a need to improve processing efficiency and mechanical properties while reducing energy consumption.
Innovation Solution
A method involving the use of a pre-processed material obtained from a weight-reduced preformed board element, combined with virgin material, is formed under controlled heat and pressure in a double-belt press to create a board layer with improved mechanical properties and reduced energy requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If materials from various sources are blended in known recycling processes, then recycling is achieved, but the precise amount and ratios of various materials become unknown, compromising panel quality
Solution Approach 1:
The invention segments the recycling process into distinct stages: separating cut-off material from the core, processing it separately, and then recombining it with virgin material in controlled ratios. This segmentation allows precise control over material composition while maintaining recycling benefits.
Solution Approach 2:
The invention changes the parameter of material processing by transforming cut-off material into a standardized pre-processed material through controlled processing parameters (heat, pressure, time), then combining it with virgin material in specific ratios to achieve desired composition and quality.
2Reliability
If cut-off material is recycled completely to produce a new core, then recycling is improved, but the processing time and energy consumption increase substantially
Solution Approach 1:
The invention applies preliminary action by pre-processing the cut-off material (grinding, separating, drying) before the main extrusion process. This preliminary preparation reduces the energy required during the main processing stage and enables better control over the final product quality.
Solution Approach 2:
The invention maintains continuity of useful action by integrating the recycling process into the main production flow. The pre-processed material is fed continuously into the extruder alongside virgin material, eliminating idle time and reducing total energy consumption compared to batch processing.
3Productivity
If known manufacturing methods are used, then production is achieved, but processing efficiency and mechanical properties need improvement
Solution Approach 1:
The invention uses composite materials by combining pre-processed recycled material with virgin material in specific ratios. This composite approach allows optimization of both mechanical properties and processing efficiency, as the blend can be tuned to achieve desired strength characteristics while improving productivity.
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
This approach reduces processing time, increases manufacturing capacity, and enhances mechanical properties such as flexural strength and modulus, while using less energy and maintaining consistent material composition.
Implementation Method 1
applying heat and pressure to the pre-processed material and the virgin material in a press
Implementation Method 2
heat and mechanical energy may be needed to gel and/or fuse the thermoplastic materials
Implementation Method 3
applying heat and pressure to the pre-processed material and the virgin material in a press
Data Source
AI summary
A method for manufacturing a board element, such as a floor element, including an at least partially recycled board layer. The method includes providing a pre-processed material from at least one weight-reduced preformed board element, preferably being obtained by removal of material from a rear side thereof, wherein the pre-processed material includes a thermoplastic material, and providing a virgin material including a thermoplastic material. The method further includes applying heat and pressure to the pre-processed material and the virgin material in a double-belt press to form the board layer, and forming a board element comprising the board layer. Also, a corresponding assembly for manufacturing of a board element.