Floor Panel Powder Overlay Segmentation
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Solution Overview
Problem
Traditional laminated panel production methods require impregnated decorative papers, which are costly, have limited shelf life, and necessitate precise positioning, leading to inefficiencies and production challenges.
Innovation Solution
A method involving digital printing on unimpregnated papers, applying a resin, and using powder or liquid overlays with thermosetting resins and wear-resistant particles, followed by heat and pressure curing, to produce laminated products with improved flexibility and surface design accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If impregnated decorative papers are used, then the surface quality and wear resistance are improved, but the production cost increases and shelf life is limited to 6-12 months
Solution Approach 1:
The patent separates the decorative paper application from the resin impregnation process. The decorative paper is applied first in an unimpregnated state, then resin is applied separately in a subsequent step, allowing the paper to have extended shelf life while still achieving the desired surface quality through controlled impregnation during production
Solution Approach 2:
The decorative paper is applied to the core in advance before resin impregnation occurs. This preliminary positioning allows for easier handling and storage of unimpregnated papers with longer shelf life, while the resin impregnation is performed later during the production process to ensure surface quality
2Reliability
If impregnated decorative papers are used, then the surface quality is improved, but the production cost increases due to climate controlled storage and minimum quantity requirements
Solution Approach 1:
The process is divided into separate stages: decorative paper application, drying, resin application, and pressing. This segmentation allows unimpregnated papers to be stored and handled without expensive climate control, reducing production costs while maintaining surface quality through controlled resin application later
Solution Approach 2:
The patent treats the decorative paper as a component that can be handled and stored in a simpler, more economical manner by applying it unimpregnated. This approach eliminates the need for expensive climate-controlled storage and minimum quantity impregnation requirements, reducing overall production costs
3Reliability
If impregnated decorative papers are used, then the surface quality is improved, but the positioning precision requirements increase due to swelling and shrinking during impregnation
Solution Approach 1:
The decorative paper is positioned on the core before resin impregnation occurs. By performing the positioning action preliminarily while the paper is in its stable, unimpregnated state, the patent avoids the positioning difficulties caused by swelling and shrinking that occur during impregnation, thereby reducing precision requirements
Solution Approach 2:
The patent separates positioning from impregnation into distinct sequential steps. The paper is positioned first in a stable state, then resin is applied separately. This segmentation eliminates the problem of positioning difficulty during impregnation, as the paper dimensions remain stable during the positioning phase
4Adaptability or versatility
If digital printing is applied on paper before impregnation, then production flexibility is improved, but the positioning and alignment complexity increases
Solution Approach 1:
Digital printing is performed on the decorative paper before the paper is applied to the core and before resin impregnation occurs. By completing the printing operation preliminarily on the flat, accessible paper surface, the system gains production flexibility while avoiding the positioning and alignment complexities that would arise if printing had to occur after paper application and during the constrained impregnation process
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 reduces costs, increases production flexibility, and achieves surface quality comparable to or exceeding traditional methods without the need for impregnated papers, allowing for precise décor positioning and enhanced wear resistance.
Implementation Method 1
applying a by melamine formaldehyde resin impregnated printed decor paper 2 on the other side of the core 3; applying a melamine formaldehyde resin impregnated transparent overlay paper 1 with wear resistant particles... and curing the resins by applying heat and pressure
Implementation Method 2
the decorative paper swells and shrinks during impregnation
Implementation Method 3
curing the resins by applying heat and pressure in a continuous or discontinuous press
Implementation Method 4
curing the resins by applying heat and pressure in a continuous or discontinuous press
Data Source
Figure 1a~1d
Figure 2a~2d
Figure 3a~3d
AI summary
The disclosure relates to a floor panel comprising a core (3), a balancing layer (4), and a surface layer comprising a decorative paper (2), a protective transparent paper (1b), a first powder-based sublayer (12) arranged under the decorative paper (2), and a second powder-based sublayer (1a) arranged between the decorative paper (2) and the protective transparent paper (1b). The first (12) and second (1a) powder-based sublayers comprise fibers having an average length which is smaller than the average length of the fibers in the decorative paper (2) and the protective transparent paper (1b).