Waterproof Panel With Mineral Composite Core
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Solution Overview
Problem
Existing waterproof thermoplastic panels suffer from uneven surfaces due to substrate irregularities and excessive shrinking and expansion from temperature changes, requiring improved rigidity and reduced layer complexity without reinforcement or adhesive layers.
Innovation Solution
A waterproof panel with a laminate structure comprising a composite core layer of mineral material and thermoplastic material, where the mineral material constitutes at least 60% by weight, providing enhanced rigidity and temperature resistance, and a top layer fused to the core layer without an adhesive, using a fusion bonding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the panel is made from thermoplastic materials to provide waterproofing, then water resistance is improved, but the panel becomes too flexible and allows visible unevenness from substrate irregularities
Solution Approach 1:
The core layer uses a composite material consisting of thermoplastic polymer (providing waterproofing) and mineral filler such as calcium carbonate or magnesium oxide (providing rigidity). This composite structure maintains water resistance while achieving the necessary stiffness to bridge substrate irregularities.
2Ease of operation
If the panel uses predominantly thermoplastic material for flexibility, then ease of installation is improved, but excessive shrinking and expansion occurs due to temperature changes
Solution Approach 1:
The panel achieves optimal dimensional stability by controlling the ratio of thermoplastic polymer to mineral filler in the core layer, ensuring the mineral content provides sufficient thermal stability while the polymer matrix maintains workability during installation.
Solution Approach 2:
The composite core layer combines thermoplastic polymer with mineral filler to create a material that balances flexibility for installation with dimensional stability during service, reducing excessive shrinking and expansion from temperature changes.
3Strength
If reinforcement layers and adhesive layers are added to improve rigidity, then panel stiffness is improved, but the laminate structure becomes more complex
Solution Approach 1:
The invention merges the functions of the core layer and reinforcement layer into a single composite core layer that provides both structural support and rigidity, eliminating the need for separate reinforcement and adhesive layers while simplifying the overall laminate structure.
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 achieves significant rigidity, reduced shrinkage, and improved temperature resistance, allowing for stable installation and resistance to chemicals and water, while eliminating the need for reinforcement and adhesive layers, resulting in a durable and dimensionally stable waterproof solution.
Implementation Method 1
the core layer and the top layer are fixed to each other by virtue of a fusion bonding which has been formed under heat and pressure
Implementation Method 2
applying pressure and heat on the assembled structure such that a fusion bonding is established between the top layer and the molten core layer
Data Source
AI summary
The invention relates to a panel suitable for constructing a waterproof floor or wall covering, wherein the panel has a substantially planar top surface, a substantially planar bottom surface, and at least four substantially linear side edges. The invention also relates to a process for producing a panel according to the invention. The invention further relates to a panel obtainable by said process according to the invention.