Building Panel Overlay via Liquid Binder Impregnation
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Solution Overview
Problem
Current methods for producing building panels, such as laminate flooring, face challenges in achieving improved staining resistance, transparency, and uniform distribution of additives, often resulting in surfaces with limited cleaning ease and high opacity due to incomplete impregnation and adhesion issues between the resin matrix and wear-resistant particles.
Innovation Solution
A method involving the formation of a mix comprising wood particles, a solvent, and a binder, where the binder is dissolved in the solvent to ensure homogeneous distribution and impregnation of wood particles, improving adhesion and distribution of additives, followed by application and curing under heat and pressure to form a surface layer or overlay.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If dry mixing process is used to produce powder overlay, then production efficiency is improved, but uniform distribution of binder and additives is worsened
Solution Approach 1:
The invention changes the physical state of the binder from dry powder to liquid solution form. By dissolving the binder in a solvent, the mixture becomes a slurry that can be evenly distributed and applied to the decorative layer, ensuring uniform distribution of binder and additives while maintaining production efficiency.
Solution Approach 2:
The invention introduces a solvent as an intermediary substance to dissolve the binder and create a homogeneous slurry. This intermediary medium enables uniform distribution of the binder and additives, solving the distribution problem inherent in dry mixing processes.
2Ease of manufacture
If conventional overlay methods are used, then production process is simple, but staining resistance and transparency are worsened
Solution Approach 1:
The invention changes the physical state of the binder from dry to liquid solution, enabling the binder to properly impregnate wood particles and form a homogeneous matrix. This parameter change improves staining resistance and transparency while maintaining relative simplicity in the production process.
Solution Approach 2:
The invention creates a composite slurry mixture comprising wood particles, dissolved binder, solvent, and additives. This composite approach ensures proper impregnation and adhesion, leading to improved staining resistance and transparency in the final overlay.
3Ease of manufacture
If binder is applied in dry form, then application process is simple, but impregnation and adhesion of wood particles is worsened
Solution Approach 1:
The invention dissolves the binder in a solvent to create a liquid slurry, changing its physical state from dry powder to liquid solution. This enables the binder to effectively impregnate wood particles and form strong adhesion bonds, significantly improving impregnation and adhesion quality.
Solution Approach 2:
The invention uses a liquid-based slurry system where the solvent acts as a carrier fluid, enabling the binder to flow and penetrate wood particles effectively. This hydraulic approach improves impregnation and adhesion compared to dry powder application.
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 enhances the staining resistance and transparency of the building panels, reduces the risk of micro pores, and facilitates easier cleaning, while also improving the distribution and effectiveness of additives, leading to a more durable and visually appealing surface.
Implementation Method 1
a binder, wherein the binder is dissolved in the solvent
Implementation Method 2
the binder impregnates the wood particles
Implementation Method 3
forming a surface layer or an overlay by applying heat and pressure to the mix
Data Source
Figure 1~2
Figure 3a~3b
Figure 4~6
AI summary
The present disclosure relates to a method for producing a building panel. The method comprises forming a mix (2) comprising wood particles (14), a solvent, a binder (19) and at least one additive (15), wherein the binder (19) and said at least one additive (15) are homogenously distributed in the mix (2) by means of the solvent and wherein the binder (19) impregnates the wood particles (14), drying the mix (2), applying the mix (2) on a substrate (3), and forming a layer (5) by applying heat and pressure to the mix (2).