Dual-Side Decorated Plate Coating Process Merging Steps
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Solution Overview
Problem
The existing process for producing decorated plates or boards coated on both sides requires separate working steps for applying layers on the top and underside, which complicates the process and increases operational complexity.
Innovation Solution
A process where liquid glue is applied to both sides of the carrier, allowing simultaneous application and fixation of web materials, followed by a hardenable resin composition being scattered and melted or sintered, then processed in a heatable press for hardening, enabling a single-step application of layers on both sides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate working steps are used for applying layers on top side and underside, then each side can be processed independently, but the process complexity and operational complexity increase
Solution Approach 1:
The patent combines the application of web material and protective layer on both sides of the carrier into a single working step. The carrier is fed through the apparatus, and both sides are simultaneously coated with liquid glue, laminated with web materials, and covered with protective layers in one continuous passage, eliminating the need for separate processing steps for each side.
Solution Approach 2:
The apparatus is designed to perform multiple functions simultaneously: applying liquid glue to both sides of the carrier, laminating web materials on both sides, applying protective layers, and conducting hot-pressing and hardening operations all in one integrated system that processes both sides of the carrier in a single pass.
2Strength
If impregnated decorative paper is used, then adhesion is improved, but dimensional changes occur requiring additional measures to maintain register relationship
Solution Approach 1:
The patent changes the physical state and composition of the resin from impregnated form to powder form applied after lamination. The resin composition is applied as a powder that is subsequently melted and hardened, which eliminates the dimensional changes associated with pre-impregnation while still achieving strong adhesion through the liquid glue layer and controlled hardening process.
3Strength
If web material is impregnated with resin prior to lamination, then binding strength is improved, but the web material undergoes dimensional changes
Solution Approach 1:
The patent applies liquid glue to the carrier surface before lamination, which preliminarily prepares the bonding surface. The web material is then laminated to this glue layer, and the binding strength is further consolidated during the hot-pressing and hardening step, achieving strong binding without pre-impregnating the web material itself.
Solution Approach 2:
The resin is applied in powder form after lamination rather than in impregnated form before lamination. This parameter change in the state and timing of resin application eliminates the dimensional changes that would otherwise occur in the web material, while still achieving the desired binding strength through the liquid glue and controlled hardening process.
4Manufacturing precision
If separate processing steps are used for top side and underside, then quality control is easier, but productivity decreases
Solution Approach 1:
The patent merges all processing operations for both sides of the carrier into a single continuous working step. The carrier passes through the apparatus once, and both sides receive liquid glue application, web material lamination, protective layer application, hot-pressing, and hardening simultaneously, thereby maintaining quality control while significantly improving productivity.
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 simplifies the production process, reduces equipment requirements, and improves the clarity and brilliance of the decoration by eliminating the need for impregnated materials and minimizing residual moisture, while allowing for the incorporation of additives without non-homogeneities.
Implementation Method 1
liquid glue is applied to both sides of the carrier, allowing simultaneous application and fixation of web materials
Implementation Method 2
a hardenable resin composition in powder form is scattered on to the first web on the top side of the carrier and at least partially melted or sintered by heating
Implementation Method 3
hardening of the glue and the resin composition are effected under pressure and heat
Implementation Method 4
it is subjected under pressure and heat to hardening by condensation and crosslinking reactions
Data Source
AI summary
In the production of decorated plates coated on both sides, the supporting material has to be provided with the coatings for the top side and the bottom side in a plurality of passes. This is simplified significantly by firstly coating both sides with a liquid glue, applying webs of the decorative paper or, if appropriate, of a backing paper or of a nonwoven to these layers, applying, after the glue has dried, a pulverulent composition comprising a resin which can be melted and cured by heating to the top side of the first web on the top side of the plate, partially melting or melting this composition and finally curing the glue and resin composition under pressure and heat.