Decorative Laminate Sheet Composition for Non-Combustible Thin Boards
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Solution Overview
Problem
Conventional non-combustible decorative boards are thick and heavy, leading to structural integrity issues and difficulties in manufacturing, especially when compared to thinner melamine decorative boards, resulting in recognizable butt ends and increased operational challenges.
Innovation Solution
A decorative board is developed using a prepreg with a binder component comprising a thermoplastic resin and a thermosetting resin, along with an endothermic metal hydroxide, which is integrated with a thermosetting resin impregnated decorative paper, allowing for a thinner, more manageable, and non-combustible design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional non-combustible decorative board is used with thick substrate (approximately 3 mm), then non-combustibility is achieved, but the board thickness becomes large and heavy, resulting in recognizable butt end surfaces and structural integrity issues
Solution Approach 1:
The invention uses a composite binder component consisting of thermoplastic resin and thermosetting resin in a specific ratio (1:0 to 0.5:1 in solid content), combined with endothermic metal hydroxide particles. This composite material system achieves non-combustibility through the synergistic effect of the thermosetting resin providing structural integrity and the endothermic metal hydroxide absorbing heat and releasing water vapor to suppress combustion, while the thermoplastic resin enhances elasticity and flexibility, enabling thin board construction without compromising fire resistance
Solution Approach 2:
The invention changes the key parameter of binder composition by specifying a mixing ratio of thermoplastic resin to thermosetting resin of 1:0 to 0.5:1 in solid content, and controls the content of endothermic metal hydroxide at 30-80 mass% of the total binder component. These parameter optimizations enable the binder to achieve both fire resistance and sufficient mechanical strength at reduced thickness (0.6-0.8 mm), resolving the contradiction between thickness and non-combustibility
2Reliability
If a conventional non-combustible decorative board with thick substrate is used, then non-combustibility is achieved, but the board becomes heavy and difficult to operate in manufacturing processes
Solution Approach 1:
The invention optimizes the binder component parameters by controlling the mixing ratio of thermoplastic resin to thermosetting resin (1:0 to 0.5:1 in solid content) and the content of endothermic metal hydroxide (30-80 mass% of total binder). This parameter optimization reduces the required thickness to 0.6-0.8 mm while maintaining non-combustibility, thereby reducing weight and improving ease of handling in manufacturing processes such as cutting, drilling, and assembly operations
Solution Approach 2:
The invention employs a thin film structure (0.6-0.8 mm thickness) made possible by the enhanced elasticity from thermoplastic resin in the binder component. This thin film construction maintains fire resistance while significantly improving flexibility and ease of operation during manufacturing processes, allowing for easier cutting, drilling, shaping, and installation compared to conventional thick boards
3Length of stationary object
If thermoplastic resin and thermosetting resin are mixed in a specific ratio with endothermic metal hydroxide, then non-combustibility is achieved in thin boards, but the binder composition becomes more complex
Solution Approach 1:
The invention creates a composite binder material system combining thermoplastic resin, thermosetting resin, and endothermic metal hydroxide particles. While this composite composition provides enhanced functionality (fire resistance, elasticity, strength), it simplifies the overall structure by integrating multiple functions into a single binder layer, eliminating the need for separate fire-retardant treatments or additional functional layers that would increase complexity
Solution Approach 2:
The binder component serves multiple functions simultaneously: the thermosetting resin provides structural strength and adhesion, the thermoplastic resin enhances elasticity and flexibility, and the endothermic metal hydroxide delivers fire resistance through heat absorption and water vapor release. This multi-functional integration into a single binder system simplifies the overall board structure and manufacturing process while achieving thin board construction with non-combustibility
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
The solution achieves non-combustibility in thinner boards (0.6-0.8 mm), improved elasticity, reduced warpage, and enhanced processing and handling capabilities, while maintaining structural integrity and adhesion.
Implementation Method 1
an endothermic metal hydroxide
Data Source
Figure 1~2
AI summary
A decorative board 5 includes: a prepreg 2 that includes (a) a binder component including: (a1) at least one thermoplastic resin selected from a group consisting of acrylic resin having a glass-transition temperature Tg exceeding 0°C, vinyl chloride resin having a glass-transition temperature Tg exceeding 0°C, acrylic urethane, and aqueous polyurethane resin, and (a2) a thermosetting resin, a mixing ratio of the (a1) at least one thermoplastic resin to the (a2) thermosetting resin being 1:0-0.5 in solid content ratio, and (b) an endothermic metal hydroxide; and a thermosetting resin impregnated decorative paper 1, wherein the prepreg and the thermosetting resin impregnated decorative paper are stacked and integrated.