Decorative Timber Composite Panels With Pressure-Cured Resin
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Solution Overview
Problem
Existing timber composites exhibit low density and low strength, limiting their viable applications, particularly in decorative and construction materials, and are prone to damage or wear due to their low density.
Innovation Solution
A method involving the application of thermosetting adhesive to timber layers, followed by simultaneous pressure and heat treatment, allows the adhesive to penetrate and cure within the timber layers, increasing density and strength by up to 50% and enhancing mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied to timber layers and pressure and heat are applied simultaneously to penetrate and cure the adhesive, then density and strength increase by up to 50%, but manufacturing complexity increases
Solution Approach 1:
The patent combines the pressure application and heat treatment steps into a single simultaneous operation. The pressure device includes heating elements that apply both compressive force and thermal energy at the same time, allowing the adhesive to penetrate and cure within the timber layers during one integrated process rather than sequential steps, thereby achieving high strength while managing manufacturing complexity.
Solution Approach 2:
The patent utilizes changes in physical parameters (temperature and pressure) to achieve adhesive penetration and curing. By controlling and simultaneously adjusting these parameters, the process achieves deep adhesive penetration and complete curing within the timber structure, resulting in density and strength increases of up to 50%.
2Shape
If low density timber is used for scraping to create embossed effect, then decorative appearance is achieved, but durability and resistance to damage decrease
Solution Approach 1:
The patent creates a composite structure where adhesive is impregnated deep into the timber layers and cured under pressure and heat. This forms a reinforced composite material that maintains the decorative embossed appearance created by scraping low-density timber, while the cured adhesive network throughout the structure provides enhanced durability and resistance to damage and wear.
Solution Approach 2:
The patent applies different properties to different regions: the surface is scraped to create the decorative embossed appearance, while the interior structure is impregnated with cured adhesive to provide strength and durability. This local differentiation allows the timber to exhibit both aesthetic quality and structural reliability.
3Stability of the object's composition
If plywood layers are bonded with adhesive for construction material, then structural integrity is improved, but density and strength remain low limiting applications
Solution Approach 1:
The patent applies preliminary action by first impregnating the timber layers with adhesive under pressure, then applying heat to cure the adhesive in situ. This preliminary penetration of adhesive into the timber structure before final bonding creates a reinforced composite that achieves both structural integrity and high strength, overcoming the limitations of conventional plywood.
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 process results in a denser and stronger timber composite with improved hardness and durability, maintaining natural grain appearance, suitable for decorative applications like flooring without the need for additional wear-resistant coatings.
Implementation Method 1
applying adhesive to one or more timber layers, applying pressure to the one or more timber layers, and heating the timber layers, such that the adhesive penetrates into the one or more timber layers and cures to form the timber composite
Implementation Method 2
The timber composite may comprise a plurality of timber layers and a thermosetting resin that has penetrated the wood grain of the timber layers
Data Source
AI summary
A decorative panel including a substrate material and decorative top layer includes a compressed timber layer with a permanent increased density. The panel is a floor panel including a mechanical coupling so a locking is created in a vertical direction perpendicular to a plane of the coupled panels, and in a horizontal direction perpendicular to coupled edges and in the plane of the coupled panels. The coupling allows coupling by a downward-directed movement where a first edge includes a male coupling part that can be pushed into a recess of a female coupling part to lock in the vertical direction due to a pair of a cooperating heel of the male coupling part and the recess of the female coupling part, wherein the recess is formed by substrate material of the second edge and a resilient element arranged in the substrate material of the second edge.