Symmetrical Embossed Laminate for Bonding and Warping Control
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Solution Overview
Problem
Conventional laminates for carrier boards require separate preparation of decorative and bonding surfaces, leading to asymmetry, increased storage and handling complexities, and potential moisture penetration due to sanded surfaces, necessitating additional adhesive and separate inventory for each decor.
Innovation Solution
A laminate with embossed structures on both decorative layers, allowing for symmetrical double-sided use with enhanced bonding properties and reduced moisture penetration, enabling thinner profiles and unified inventory management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the back of the laminate is sanded to improve bonding, then bonding properties are improved, but the laminate becomes asymmetrical and prone to warping
Solution Approach 1:
The patent applies asymmetry in reverse by creating symmetry - both sides of the laminate are provided with embossed structures during the pressing process, eliminating the asymmetry that would otherwise result from sanding only one side. This symmetrical design prevents warping while maintaining bonding properties on both surfaces.
Solution Approach 2:
Instead of sanding the back surface after laminate production, the embossed structure is created preliminarily during the pressing process itself. The pressing means with embossed surfaces impart the bonding-enhancing structure to both sides of the laminate before it is removed from the press, eliminating the need for subsequent sanding operations.
2Adaptability or versatility
If separate laminates are produced for each decor, then decorative variety is achieved, but inventory complexity and storage requirements increase
Solution Approach 1:
The laminate is designed with universal applicability - both decorative surfaces have embossed structures that provide bonding properties, allowing either side to be bonded to a carrier board. This multi-functionality enables a single laminate design to serve multiple decorative purposes, reducing the need for separate inventory for different applications.
Solution Approach 2:
Conventionally, only one side of a laminate is decorative while the other is plain and intended for bonding. This patent inverts that convention by making both sides decorative with embossed structures, allowing either side to serve as the bonding surface. This eliminates the need to produce separate laminates for different decor orientations.
3Length of moving object
If the laminate thickness is reduced, then material usage and weight are decreased, but structural integrity and bonding surface area are compromised
Solution Approach 1:
The embossed structures create a micro-roughness on the bonding surfaces that increases effective surface area and mechanical interlocking capability. This allows thinner laminates to achieve sufficient bonding strength through enhanced surface geometry rather than relying solely on increased thickness.
Solution Approach 2:
Instead of increasing thickness in the vertical dimension to improve bonding, the patent creates embossed structures that add surface area in the horizontal dimension. This dimensional shift allows bonding strength to be enhanced without increasing laminate thickness, maintaining thin profile while improving structural integrity.
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 embossed laminate surfaces provide improved bonding, reduced warping, and efficient adhesive usage, eliminating the need for separate laminates and simplifying storage and handling, while maintaining decorative and structural integrity.
Implementation Method 1
a drop of tap water at room temperature with a maximum diameter of 15 mm with the layer having the embossed structure assumes a contact angle above 40°
Implementation Method 2
The supply of heat and pressure causes the resins to flow and then harden
Implementation Method 3
The supply of heat and pressure causes the resins to flow and then harden
Implementation Method 4
The crosslinking of the resins, preferably reinforced by the cellulose fibers of the papers, creates a very dense material with a closed surface
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The invention relates to a laminate for applying to a support material, in particular to a support panel, having a resin-impregnated decorative layer (4) and having at least one resin-impregnated core layer (6, 8, 10), the decorative layer (4) and the at least one core layer (6, 8, 10) being suitable for being pressed together under high pressure and heat. The technical problem of improving a laminate for applying to a support material, in particular a support panel, is solved in that a resin-impregnated layer (12) arranged opposite the decorative layer (4) is also designed as a decorative layer. The invention also relates to a method for producing a laminate.