Building Panel Powder Layer Curing Method
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Solution Overview
Problem
The production of thick, high-quality decorative surface layers with balanced and stable properties in building panels, especially in 'paper-free' Wood Fibre Floors, is challenging due to uneven shrinkage and difficulty in handling powder-based layers in high-speed production processes.
Innovation Solution
A method involving the application of a first powder-based mix with wood fibres and a thermosetting binder on a core, followed by drying and turning it to apply a second decorative layer, allowing simultaneous curing under heat and pressure to form a balancing and/or protective layer, which stabilizes the panel and enables efficient handling and pressing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thick powder-based decorative surface layer is applied on a core, then wear resistance and decorative quality are improved, but shrinkage during curing becomes uneven and handling difficulty increases
Solution Approach 1:
The method applies a liquid substance to the powder-based mix before curing to pre-establish binding between particles. This preliminary action prevents uneven shrinkage and maintains layer integrity during handling and pressing operations, resolving the contradiction between achieving thick wear-resistant layers and maintaining ease of manufacture
Solution Approach 2:
The invention changes the physical state of the powder mix by introducing a liquid substance that alters particle binding characteristics. This parameter change enables the thick powder layer to maintain structural integrity during curing and handling, simultaneously achieving wear resistance and manufacturability
2Strength
If a powder-based mix is applied as a thick layer, then decorative quality and wear resistance are improved, but production cost increases
Solution Approach 1:
By changing the binding mechanism from traditional resin impregnation to a liquid-substance-based binding process, the invention reduces material costs while maintaining thick wear-resistant layers. The liquid substance enables cost-effective production of high-quality surfaces
3Strength
If a powder-based decorative layer is cured under heat and pressure, then wear resistance is improved, but panel flatness becomes difficult to maintain
Solution Approach 1:
The liquid substance is applied before curing to pre-establish uniform binding throughout the powder layer. This preliminary action ensures even shrinkage and stress distribution during subsequent heat and pressure curing, maintaining panel flatness while achieving wear resistance
Solution Approach 2:
The introduction of liquid substance changes the curing behavior of the powder layer, enabling uniform consolidation under heat and pressure that maintains panel flatness while developing wear-resistant properties
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 method allows for cost-efficient production of building panels with balanced and stable surface layers, reducing production costs and improving the panel's wear resistance, impact resistance, and sound and moisture properties, while maintaining panel flatness under varying moisture conditions.
Implementation Method 1
curing the first and second layers simultaneously by providing heat and pressure
Implementation Method 2
drying the first powder based mix
Data Source
Figure 1a~1e
Figure 2a~2e
Figure 3~4
AI summary
A method of manufacturing a building panel with a decorative surface layer, a core and a balancing and/or protective layer, wherein the method includes applying a first layer of a first powder based mix, including wood fibers and a thermosetting binder, on a core; applying a liquid substance on the first powder based mix; drying the first powder based mix; turning the core with the dried first powder based mix such that the first powder based mix points downwards; applying a second layer on the upper part of the core; and curing the first and second layers by providing heat and pressure, wherein the first layer forms the balancing and/or protective layer and the second layer forms the decorative surface layer in the building panel.