Inline Extruded Coated Panels for Waterproof Sound-Absorbing Flooring
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Solution Overview
Problem
Existing methods for manufacturing coated panels face inefficiencies and high costs due to discontinuous production processes and the limitations of wood-based materials, which are prone to water damage and poor sound absorption.
Innovation Solution
A continuous method for manufacturing coated panels involves adhering a thermosetting resin-treated top layer to a synthetic substrate material, such as a solid plastic composite, using an adhesive in line with the extrusion process, allowing for a more efficient and cost-effective production of waterproof and sound-absorptive panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a discontinuous manufacturing process is used for coated panels, then manufacturing precision can be maintained, but productivity is reduced and production costs increase
Solution Approach 1:
The patent implements a continuous manufacturing process where the top layer material is adhered to the substrate material in a continuous manner through an extrusion line, eliminating discontinuous steps such as opening and closing presses. This continuous operation increases productivity while maintaining manufacturing precision through controlled adhesive application and consistent processing parameters throughout the continuous run.
2Object-affected harmful factors
If wood-based materials are used in panels, then aesthetic appearance is improved, but water resistance deteriorates leading to panel damage
Solution Approach 1:
The patent uses a composite structure consisting of a synthetic substrate material (such as plastic composite) that provides water resistance, combined with a top layer material (such as paper and resin) that provides aesthetic appearance and mechanical strength. The adhesive material bonds these different materials together, creating a composite panel that achieves both water resistance and structural integrity.
3Object-generated harmful factors
If a high proportion of wood-based material is used in panels, then structural integrity is maintained, but sound absorption capability is reduced
Solution Approach 1:
The patent applies different materials with specific local functions: the synthetic substrate material provides sound absorption capability in the core layer, while the top layer material provides structural integrity and aesthetic appearance. This local differentiation of material properties allows the panel to achieve both good impact sound absorption and sufficient structural strength without requiring high proportions of wood-based material throughout.
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 results in a more economic and continuous production of coated panels with improved mechanical properties and sound absorption, suitable for use in water-exposed environments, while reducing the weight and enhancing the durability of the panels.
Implementation Method 1
adhering, in a continuous manner, said top layer material to said substrate material by means of at least said adhesive material
Implementation Method 2
a top layer comprising at least a decorative layer and thermosetting resin
Implementation Method 3
extruding a synthetic substrate material in a continuous manner; said synthetic substrate material at least comprising polymeric material
Data Source
AI summary
The invention relates to a method for manufacturing a coated panel (1), said method at least comprising: the step of providing a top layer material (2) at least comprising a decorative layer (14) including thermosetting resin; the step of providing adhesive material (4); the step of extruding a synthetic substrate material (3) in a continuous manner; said synthetic substrate material (3) at least comprising polymeric material; characterized in that the method further comprises the step of adhering, in a continuous manner, said top layer material (2) to said substrate material (3) by means of at least said adhesive material (4), wherein said step of adhering takes place inline with said step of extruding said substrate material (3).