Composite Wood Flooring with Uncured Fiber-Reinforced Coating

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Solution Overview

Problem

Existing composite wood flooring for storage containers requires a multi-step process involving curing and adhesive application, which is inefficient and may not provide optimal bonding between the fiber-reinforced coating and the wood substrate.

Innovation Solution

A composite panel with a wood substrate coated by a resin matrix and fibers oriented perpendicular and parallel to the substrate's longitudinal axis, cured in a single process without adhesives, using methods like pultrusion or isobaric pressing to integrate the fibers and resin directly onto the wood surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a multi-step process with adhesive application is used to bond fiber-reinforced sheets to wood substrate, then bonding strength may be improved, but manufacturing complexity and process time increase

Engineering Contradiction:

Improvebonding strengthVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent combines the fiber reinforcement, adhesive application, and substrate bonding operations into a single integrated coating step. The fiber-reinforced adhesive coating is applied directly to the wood substrate in one continuous operation, eliminating separate curing and bonding steps while maintaining strong adhesion through the resin matrix that naturally bonds to both the fibers and substrate.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent implements a continuous coating process where the fiber-reinforced adhesive is applied and bonded to the substrate in a single continuous operation. The coating apparatus applies the adhesive coating with embedded fibers directly onto the moving substrate, maintaining continuous production flow without interruption for separate curing or bonding steps.

Inventive Principle:

Principle #20Continuity of useful action

2Ease of manufacture

If fiber-reinforced sheets are pre-cured before lamination, then handling and storage are improved, but bonding effectiveness and manufacturing efficiency decrease

Engineering Contradiction:

Improvehandling and storageVSAvoidmanufacturing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent inverts the conventional sequence by applying the fiber-reinforced adhesive in an uncured state directly to the substrate, then curing it in place. Instead of pre-curing the reinforcement separately and then bonding it, the method applies the uncured fiber-adhesive mixture and cures it during the bonding process itself, achieving both handling ease and bonding effectiveness.

Inventive Principle:

Principle #13The other way round (Inversion)

3Strength

If adhesive is applied between fiber-reinforced sheet and substrate, then bonding is achieved, but material cost and environmental impact increase

Engineering Contradiction:

ImprovebondingVSAvoidadhesive material usage

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

The patent creates a composite material system where fibers are embedded within the adhesive matrix, forming a unified fiber-reinforced adhesive coating. This composite structure provides both reinforcement and bonding functionality in a single material system, eliminating the need for separate adhesive applications and reducing overall material consumption while maintaining bonding strength.

Inventive Principle:

Principle #40Composite materials

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 enhances bonding strength and reduces manufacturing complexity by eliminating the need for adhesives and secondary curing steps, resulting in a durable and efficient composite wood flooring suitable for trailers and storage containers.

Implementation Method 1

a resin matrix around the plurality of first and second fibers

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

curing the uncured fiber-reinforced coating after applying the uncured fiber-reinforced coating onto the surface of the wood substrate

Methodology Applied

Scientific EffectThermal curing: Heating

Data Source

PatentUS9744753B2Composite wood flooring and method of making the same

Publication Date: 2017.08.29 WABASH NATIONAL CORP

AI summary

A method of making a composite panel configured for use with a flooring assembly of a trailer includes providing a wood substrate, making an uncured fiber-reinforced coating, and applying the uncured fiber-reinforced coating onto a surface of the wood substrate. The method further includes curing the uncured fiber-reinforced coating after applying the uncured fiber-reinforced coating onto the surface of the wood substrate.