Floor Panel Reinforcement Sheet Impregnation Method
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Solution Overview
Problem
Existing methods for manufacturing modular floor products face challenges in ensuring proper impregnation of glass fiber webs due to short contact times in continuous processes, leading to potential delamination, and in double belt press methods, where glass fibers can be damaged by granulate deformation or perforation, limiting flexibility in product changes.
Innovation Solution
A method where the reinforcement sheet and the first layer are pressed together after partially melting the thermoplastic material of the first layer, but before applying the second layer, allowing direct support by a rigid press element to minimize deformation and damage, and using standard granulate size to maintain production efficiency and prevent fiber damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous laminating process is used with short contact time at nip roll, then production speed is high, but impregnation of glass fiber web is insufficient leading to delamination
Solution Approach 1:
The process is divided into two distinct stages: first spreading granulate and glass fiber web separately, then compressing them together in a second step. This segmentation allows sufficient contact time for impregnation without requiring high-speed continuous laminating, thus ensuring reliable bonding while maintaining production efficiency.
Solution Approach 2:
The granulate layer is prepared and positioned on the glass fiber web before compression occurs. This preliminary arrangement ensures that when compression happens, the granulate is already in optimal position for impregnation, maximizing the effectiveness of the bonding process without requiring extended contact time.
2Reliability
If double belt press compression is applied to impregnate glass fiber layer, then impregnation is achieved, but glass fiber can be damaged by granulate deformation or perforation
Solution Approach 1:
A release film or protective layer is placed between the granulate and the glass fiber web before compression. This cushioning layer prevents direct contact between the granulate and glass fibers during the compression process, protecting the fibers from deformation or perforation while still allowing effective impregnation to occur.
3Object-affected harmful factors
If very fine granulate (microgranulate) is used to prevent fiber damage, then fiber deformation is reduced, but production efficiency decreases and investment costs increase
Solution Approach 1:
A release film or protective intermediary layer is introduced between the granulate and glass fiber web. This mediator allows the use of standard-sized granulate without causing fiber damage, as the intermediary protects the fibers during compression. This eliminates the need for expensive microgranulate production while maintaining fiber integrity and production efficiency.
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 effective impregnation and minimizes deformation of the reinforcement sheet, allowing for high production speeds and flexible product changes with consistent thickness and quality, while maintaining the integrity of the glass fibers and reducing production costs.
Implementation Method 1
at least partially melting the thermoplastic materials of the first layer and the second layer
Implementation Method 2
at least partially melting the thermoplastic materials of the first layer and the second layer
Implementation Method 3
wherein the pressed complex is cooled
Data Source
AI summary
A method for manufacturing a panel including a reinforcement sheet comprises the steps of: providing a first layer of thermoplastic material, providing a reinforcement sheet, laying the reinforcement sheet and the first layer onto each other, applying a second layer of thermoplastic material on top of the reinforcement sheet at a side facing away from the first layer, at least partially melting the thermoplastic materials of the first layer and the second layer, adhering the at least partially melted first layer, the at least partially melted second layer and the reinforcement sheet to each other so as to form the panel, wherein the reinforcement sheet and the first layer are adhered to each other by pressing them together after at least partially melting the thermoplastic material of the first layer, but before applying the second layer of thermoplastic material onto the reinforcement sheet.