Dry Powder Stabilization via Steam Condensation

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Solution Overview

Problem

Existing methods for producing fibre-based building panels, such as Wood Fiber Floor panels, face challenges in stabilizing dry powder mixtures during handling and pressing, leading to uneven water distribution and unintentional water drops, which affect the visual and technical properties of the panels and slow down production.

Innovation Solution

Applying steam, preferably pure water steam with additives, to the dry powder layer on a core, either uniformly or unevenly to create patterns, stabilizes the mixture and prevents powder loss during handling and pressing, allowing for immediate pressing and improved moisture control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If water is sprayed to stabilize the dry powder mix, then the powder is stabilized, but water distribution becomes uneven and water drops fall on the powder layer

Engineering Contradiction:

Improvepowder stabilizationVSAvoidwater distribution uniformity

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The patent introduces a mesh belt as an intermediary carrier between the water spray system and the powder layer. The mesh belt absorbs the sprayed water and subsequently distributes it uniformly to the powder layer through capillary action and controlled release, preventing direct water drops from contacting the powder while ensuring even moisture distribution for proper stabilization.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If water is sprayed to stabilize the powder, then the powder is stabilized, but production speed decreases due to waiting time

Engineering Contradiction:

Improvepowder stabilizationVSAvoidproduction speed

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The mesh belt is pre-sprayed with water before the powder is applied to the conveyor. This preliminary wetting of the mesh belt allows for immediate and uniform water transfer to the powder layer as it is deposited, eliminating the need for waiting time and enabling continuous high-speed production while ensuring proper powder stabilization.

Inventive Principle:

Principle #10Preliminary action

3Stability of the object's composition

If water is sprayed to stabilize the powder, then the powder is stabilized, but unintentional water drops affect product quality

Engineering Contradiction:

Improvepowder stabilizationVSAvoidwater drops on powder layer

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The mesh belt serves as a protective intermediary that intercepts sprayed water and prevents direct contact with the powder layer. The belt's mesh structure and capillary properties ensure that water is held and released in a controlled manner, completely eliminating unwanted water drops from falling onto the powder while maintaining effective stabilization.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Manufacturing precision

If steam is applied to the powder layer, then moisture control is improved and powder loss prevented, but energy consumption increases

Engineering Contradiction:

Improvemoisture distribution controlVSAvoidsteam generation energy

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent utilizes the phase transition of water from liquid to steam and back to liquid condensate. Steam is applied to the powder layer where it condenses, releasing latent heat that rapidly and uniformly distributes moisture throughout the powder. This phase change mechanism provides superior moisture control efficiency compared to liquid spray, achieving better stabilization with reduced overall energy consumption by utilizing the high heat of condensation.

Inventive Principle:

Principle #36Phase transitions

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 method ensures a more uniform color and pattern control, prevents powder loss, and enhances production efficiency by allowing for faster processing and improved product quality.

Implementation Method 1

Applying steam to the powder layer stabilizes the mixture and prevents powder loss during handling and pressing

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 2

Applying steam, preferably pure water steam with additives, to the dry powder layer on a core

Methodology Applied

Scientific EffectCondensation: Condensation

Data Source

PatentUS11040371B2Production method

Publication Date: 2021.06.22 VÄLINGE INNOVATION AB

AI summary

A method for producing a panel including a core and a decorative surface layer is disclosed. The method includes the step of applying a dry powder layer on the core. The method includes the step of applying steam on a dry powder layer on the core. Thereafter heat and pressure are applied to the powder layer in order to bond the powder together.