Co-Extruded Edge Profile for Sheet Material to Reduce Layer Complexity
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Solution Overview
Problem
The existing multi-layer structure for edge profiles is complex, requiring precise matching of primers and decorative layers, which can negatively affect mechanical properties and processing efficiency.
Innovation Solution
A simplified edge profile structure where the decorative reason is a plastic layer co-extruded with the base body, eliminating the need for separate primers and simplifying the layer structure, with the decorative ground having a layer thickness of 5 to 100 µm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a multi-layer structure with primer, decorative base, and protective varnish is used, then the final decoration quality is improved, but the device complexity and manufacturing complexity increase
Solution Approach 1:
The patent combines the decorative base layer and protective varnish into a single co-extruded layer during base body production. This merging eliminates the need for separate primer and protective varnish applications, reducing the number of manufacturing steps while maintaining the decorative quality through integrated color and protection
Solution Approach 2:
The co-extruded layer serves multiple functions simultaneously: it provides the decorative base color, acts as a primer for the decorative print, and offers protective varnish properties. This multi-functionality reduces the overall layer structure complexity while achieving the same decoration quality
2Manufacturing precision
If multiple separate layers are applied to the base body, then the final decoration is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The decorative base and protective varnish are merged into a single co-extruded layer produced during base body extrusion. This eliminates multiple separate application steps (primer application, decorative base application, protective varnish application), significantly improving ease of manufacture while maintaining decoration quality
Solution Approach 2:
The decorative base layer is co-extruded with the base body in advance, before the decorative print is applied. This preliminary action integrates the decorative base into the base body structure itself, eliminating the need for separate application steps and simplifying the overall manufacturing process
3Manufacturing precision
If a multi-layer structure with primer and decorative base is used, then the final decoration quality is improved, but the loss of time in production increases
Solution Approach 1:
The decorative base and protective varnish are combined into a single co-extruded layer produced during base body extrusion. This eliminates the sequential time required for separate application, drying, and curing of multiple layers, significantly reducing production time while maintaining decoration quality
Solution Approach 2:
The co-extrusion process creates the decorative base layer continuously during base body production, without interruption or separate processing steps. This continuous action eliminates idle time between layers and maintains steady production flow, reducing overall production time
4Manufacturing precision
If separate primer and decorative base layers are applied, then the final decoration is improved, but the mechanical properties of the base body deteriorate
Solution Approach 1:
The decorative base and protective varnish are merged into a single co-extruded layer made from the same plastic material as the base body. This integration ensures uniform mechanical properties throughout the structure, avoiding the embrittlement or adhesion issues that can arise from separate chemical layers
Solution Approach 2:
The co-extruded decorative base layer uses the same plastic material as the base body, creating a homogeneous structure with uniform mechanical properties. This eliminates the interface between dissimilar materials that can create weak points, maintaining consistent strength and flexibility throughout
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 the complexity of the edge profile production, maintains the mechanical properties of the base body, and optimizes recycling and layer adhesion, resulting in a more efficient and cost-effective manufacturing process.
Implementation Method 1
The base body can be extruded in a width that is typically 1 to 4 mm wider than the narrow side of the sheet. It is also known to extrude a strand several times wider and then divide it lengthwise into several base bodies
Implementation Method 2
the decorative base co-extruded with the base body has a layer thickness in a range of 5 to 100 μm
Data Source
Figure 1
Figure 2a~2b
Figure 2c~2d
AI summary
The present invention relates to an edge profile (1) for a sheet-like material (2) comprising a layered structure (3) with a main body (4) made of plastic which has a first base colour tone, with a decorative base material (5) which has a second base colour tone, and with a decorative print (6), wherein a final decoration (7) which has a third base colour tone is formed at least from decorative base material (5) and decorative print (6) together, wherein the decorative base material (5) is a layer arranged between main body (4) and decorative print (6). For easier production, the invention proposes that the decorative base layer (5) is a layer of plastic co-extruded with the main body (4). The invention also relates to a sheet-like material with a corresponding edge profile (1).