Composite Board Production via Single-Step Hot Pressing
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Solution Overview
Problem
The production of laminated composite panels is complex and time-consuming, with high costs due to the need for multiple pressing operations and the use of adhesives.
Innovation Solution
A method involving the integration of a wood-based panel as a middle layer within a layered structure of cellulose fiber webs, which are pressed together in a single operation to form a composite panel, eliminating the need for separate adhesive application and reducing production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laminated panels are produced by coating and pressing kraft papers impregnated with phenolic resin and decorative papers impregnated with melamine resin together at elevated temperature, then wear resistance and scratch resistance are improved, but production complexity and time increase
Solution Approach 1:
The patent combines multiple separate production operations into a single integrated process. Specifically, it merges the production of the laminated panel with the attachment to the substrate panel into one simultaneous pressing operation, eliminating the need for separate adhesive application and curing steps, thereby reducing production complexity while maintaining wear resistance through the impregnated paper layers
2Strength
If laminated panels are produced by separate coating and pressing operations followed by adhesive application, then mechanical strength is achieved, but production time increases
Solution Approach 1:
The patent merges the laminated panel formation and substrate attachment into a single pressing operation. The impregnated papers provide both the laminated structure and the bonding function, eliminating sequential steps and reducing production time while maintaining mechanical strength through the integrated pressing process at elevated temperature and pressure
3Reliability
If recooling presses are used to cool panels before opening to reduce vapor pressure, then safety is improved, but production cycle time increases
Solution Approach 1:
The patent modifies the moisture content parameter of the impregnated papers to be below 5%, which significantly reduces the vapor pressure generated during pressing. This parameter change allows the press to be opened safely without requiring extended recooling time, thus maintaining safety while reducing the production cycle time
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 results in a stable composite panel with reduced production costs and time, capable of high mechanical performance for applications like heavy-duty shelves and load-bearing ceiling elements, while also allowing for decorative and wear-resistant features.
Implementation Method 1
pressing the layer while increasing the pressing pressure and the temperature to form a composite panel
Implementation Method 2
pressing the layer while increasing the pressing pressure and the temperature
Implementation Method 3
recooling presses are used in the production of laminated panels, which cool the panels before the press is opened in order to reduce the vapor pressure present at high temperatures
Data Source
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AI summary
Method for producing a laminate composite board, wherein the following steps are performed: provision of a plurality of first cellulose fiber webs (1a, 1b, 1c, 1d) having an impregnation, providing a plurality of a second cellulose fiber webs (2a, 2b, 2c, 2d) having an impregnation, providing a wood material board (3), forming a lamination (4) having a top liner (4a) comprising the first cellulose fiber web (1a, 1b, 1c, 1d), having a middle layer (4b) comprising the wood material board (3), the top side (4b.1) thereof being adjacent to the top liner (4a), and having a bottom liner (4c) comprising the second cellulose fiber web (2a, 2b, 2c, 2d) and adjacent to the bottom side (4b.2) of the middle layer (4b), wherein the top liner (4a) and/or the bottom liner (4c) are formed having a thickness of at least 2 mm after the step of exiting the hot press (5), moving the laminate (4) into a hot press (5), pressing the laminate (4) while increasing the press pressure and the temperature, forming a composite board (6), and removing the composite board (6) from the hot press (5).