Decorative Panel Composite Core for Thermo-Bonded Resin Top Layers
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Solution Overview
Problem
Existing methods struggle to bond thermoplastic core materials with thermosetting resin impregnated cellulose top layers without delamination or requiring complex processes, as thermoplastics soften and melt at curing temperatures, leading to uneven thicknesses and fractures.
Innovation Solution
A decorative panel with a core layer comprising a composite material of mineral material and polymer, having a Vicat softening temperature of at least 80°C and Shore D hardness of at least 85, directly bonded to a resin-impregnated paper top layer using thermosetting resin and polymeric adhesive, eliminating the need for intermediate adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermoplastic core material is used to provide water resistance, then waterproof benefits are achieved, but the core softens and melts at curing temperatures required for thermosetting resin top layers
Solution Approach 1:
The patent modifies the core material parameters by blending thermoplastic polymer with inorganic filler to achieve a Vicat softening temperature of at least 80°C, transforming the core from temperature-sensitive to temperature-stable while maintaining waterproof properties
Solution Approach 2:
The patent creates a composite core material combining thermoplastic polymer and inorganic filler, merging the waterproof benefits of thermoplastics with the thermal stability of inorganic materials to prevent deformation during curing
2Strength
If thermosetting resin impregnated cellulose top layer is used to provide scratch resistance, then scratch resistance is improved, but delamination occurs due to bonding difficulties with thermoplastic core
Solution Approach 1:
The patent modifies the core surface parameters by increasing hardness to Shore D 85 or more, creating a surface that can withstand the high pressure and temperature of thermosetting resin curing without deforming, thereby enabling reliable bonding
Solution Approach 2:
The patent creates a composite core material with enhanced thermal and mechanical properties that serves as a stable substrate for thermosetting resin bonding, eliminating delamination issues
3Stability of the object's composition
If high pressure and heat are applied to cure thermosetting resin top layer, then curing is achieved, but the thermoplastic core deforms and melts
Solution Approach 1:
The patent fundamentally changes the core material's thermal parameters by incorporating inorganic filler to raise Vicat softening temperature to at least 80°C, allowing the core to withstand curing temperatures without deformation
Solution Approach 2:
The patent develops a composite core material that combines the processability of thermoplastics with the thermal resistance of inorganic materials, enabling the core to maintain shape stability during high-temperature curing
4Reliability
If intermediate adhesive layer is used to bond core and top layer, then bonding is achieved, but production process becomes complex
Solution Approach 1:
The patent removes the intermediate adhesive layer from the structure by directly bonding the thermosetting resin impregnated top layer to the modified core, simplifying the production process while maintaining bonding reliability
Solution Approach 2:
The patent merges the bonding function with the top layer structure itself by using thermosetting resin impregnated paper that directly adheres to the core, eliminating the need for separate adhesive layers
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 prevents core deformation during production and use, ensures strong bonding, maintains dimensional stability, and allows for efficient thermo-bonding without intermediate adhesives, providing waterproof and scratch-resistant properties.
Implementation Method 1
the core layer has a Vicat softening temperature of at least 80 degrees Celsius
Implementation Method 2
the upper core surface of the core layer has a Shore D hardness of at least 85
Implementation Method 3
at least one ply of paper is impregnated with a resin composition comprising at least one thermosetting resin
Data Source
AI summary
The invention relates to a decorative panel, in particular a floor panel, wall panel or ceiling panel, the panel comprising at least one core layer, wherein the core layer comprises a composite material comprising at least one mineral material and at least one polymer, and at least one top layer comprising at least one cellulose or lignocellulose-based ply, wherein at least one cellulose or lignocellulose-based ply is impregnated with a cured resin composition comprising at least one thermosetting resin, wherein the core layer has a Vicat softening temperature of at least 80 degrees Celsius and wherein the core layer has a Shore D hardness of at least 85.