Laminated Decorative Plate Liquid Glue Integration
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Solution Overview
Problem
The existing production methods for laminated decorative plates are complex and costly due to the need for separate production of the resin-containing intermediate layer, precise cutting and placement of the decorative layer, and the requirement for high-quality printing base paper, which limits efficiency and increases production costs.
Innovation Solution
The use of a liquid glue that is curable by pressure and/or heat, applied with the decorative layer and optionally the cover layer, eliminates the need for a separate intermediate layer and allows for simplified alignment and application of layers, including a counteracting layer, in a reduced number of production steps, using materials like urea formaldehyde or melamine formaldehyde glues and cover layers without cellulose fibers for improved transparency and abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a separate resin-containing intermediate layer is produced and applied, then the decorative layer can be firmly fixed to the core, but the production process becomes complex and costly
Solution Approach 1:
The patent combines the intermediate layer and adhesive layer into a single integrated adhesive layer applied directly to the core. This eliminates the separate production and application steps for the intermediate layer, reducing production complexity while maintaining bonding functionality through the use of liquid glue that is curable by pressure and/or heat
Solution Approach 2:
The adhesive layer serves multiple functions: it acts as both the intermediate layer (providing bonding surface) and the adhesive layer (providing bonding strength). This multi-functional design eliminates the need for separate layers and reduces production steps
2Manufacturing precision
If the decorative layer is cut to size and placed perfectly fitting onto the core plate, then alignment accuracy is improved, but production time and cost increase
Solution Approach 1:
The patent applies adhesive over the entire core surface rather than only at specific bonding points. This excessive application of adhesive ensures that the decorative layer can be positioned more easily without requiring precise cutting and placement, as the adhesive provides coverage and bonding across the entire surface
Solution Approach 2:
The use of liquid glue that is curable by pressure and/or heat changes the physical state and bonding characteristics of the adhesive. This allows for easier application and positioning of the decorative layer before curing, reducing the need for precise pre-cutting and placement
3Manufacturing precision
If high-quality printing base paper is used for the decorative layer, then pattern quality is improved, but production cost increases
Solution Approach 1:
The patent uses decorative layers that can be produced through printing or other methods that do not require high-quality base paper. The adhesive layer and production method compensate for any reductions in base paper quality, allowing pattern reproduction through means other than high-quality paper substrates
4Manufacturing precision
If the decorative layer is applied in a condition not impregnated with glue, then dimensional stability is improved, but the bonding process becomes more complex
Solution Approach 1:
The adhesive layer is applied to the core in advance and allowed to become tacky or partially cured before the decorative layer is applied. This preliminary action ensures dimensional stability of the decorative layer while simplifying the bonding process, as the adhesive is already in position and does not require complex impregnation steps
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 approach significantly simplifies and reduces the cost of producing laminated decorative plates by integrating the glue application and layer alignment into a single or two-step process, enabling continuous production without the need for precise cutting or separate impregnation, while maintaining high-quality surface relief and pattern imitation.
Implementation Method 1
a liquid glue which is curable by pressure and/or heat
Implementation Method 2
liquid glue that is curable by pressure and/or heat, applied with the decorative layer
Implementation Method 3
These materials of the cover layer may have incorporated fine powders of hard solids thus increasing the abrasion resistance
Data Source
AI summary
The invention relates to a laminated decorative plate comprising a core made of a fiber or particle material, a resinous intermediate layer on at least one side of the core, a decorative layer not impregnated with resin and having a graphic image of the surface of the imitated material, and a transparent core layer, into which the relief-like reproduction of the surface structure of the imitated material is stamped. The intermediate layer is made of liquid glue, curable by pressure and/or heat, that is applied to the core.