Hydraulically-Bonded Multilayer Panel Production
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Solution Overview
Problem
Current production techniques fail to efficiently produce large-size, thin multilayer panels with satisfactory mechanical properties and usability, particularly those with a high edge-length-to-thickness ratio, which are required for outdoor applications like floor coverings.
Innovation Solution
A method involving a hydraulically-bonded multilayer panel production process where a flowable face mixture and a dry to earth-moist core mixture are introduced into a mold, with specific component compositions and interactions to achieve optimal packing density and water demand, allowing for immediate stripping and processing of panels with edge-length-to-thickness ratios greater than 20.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional pressing processes are used with core mixture layers having high compaction, then good pressing of water from face mixture layer is achieved, but excess water arises at panel edges and incomplete activation of hydraulic binder occurs
Solution Approach 1:
The invention changes the compaction parameter of the core mixture layer to a specific range (0.90-0.98) and adjusts the water binder ratio (0.10-0.30) to optimize water distribution. This parameter optimization allows complete water absorption without excess water formation, resolving the contradiction between good water pressing and avoiding excess water at edges.
Solution Approach 2:
The invention uses a composite core mixture layer combining hydraulic binder, fines (0-100 μm), and aggregate (>100 μm) in specific proportions. This composite structure enables controlled water absorption and distribution, preventing both incomplete activation and excess water formation while simplifying the pressing process.
2Adaptability or versatility
If large-size panels with high edge-length-to-thickness ratio are produced, then outdoor application suitability is improved, but mechanical strength and usability deteriorate
Solution Approach 1:
The invention optimizes the thickness parameter (25-35 mm) and edge-length-to-thickness ratio (>20) while maintaining mechanical strength through controlled compaction (0.90-0.98) and water binder ratio (0.10-0.30). This allows production of large-size panels suitable for outdoor applications while preserving required bending tensile strength and breaking load.
Solution Approach 2:
The invention employs a composite structure with face layer and core layer having different compositions. The core layer contains hydraulic binder, fines, and aggregate in optimized ratios to provide structural strength, while the face layer provides weather resistance. This composite approach enables large-size panels to meet both dimensional requirements and mechanical strength requirements.
3Quantity of substance
If core mixture layer with low voids content is used, then panel density is improved, but water distribution and hydraulic binder activation are compromised
Solution Approach 1:
The invention sets the voids content parameter within a specific range (0.02-0.10) rather than minimizing it completely. This controlled voids content allows sufficient space for water absorption and hydraulic binder activation while maintaining adequate panel density. The water binder ratio (0.10-0.30) is simultaneously optimized to ensure complete binder activation without compromising density.
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 method enables the production of multilayer panels with high characteristic bending tensile strength and breaking load, suitable for large-size outdoor applications, overcoming issues of void content and water distribution in previous methods.
Implementation Method 1
pressing the face mixture layer with the core mixture layer into the mold to form a hydraulically-bonded, directly strippable multilayer panel
Data Source
AI summary
The invention relates to a method for producing a hydraulically-bonded multilayer panel with at least one face layer and at least one core layer, wherein the method comprises the following stepsa. introducing a flowable face mixture into a mold. The face mixture contains at least the following componentsi. face paste containing at least1. hydraulic binder and2. water; andii. aggregate. The aggregate has a mean diameter d50 determined according to ISO 13320:2009 and/or according to EN 12620 of greater than 100.0 μm;whereby a face mixture layer is formed;b. introducing a dry to earth-moist core mixture into the mold, wherein the core mixture contains at least the following componentsi. core paste containing at least1. hydraulic binder,2. fines, wherein the fines have a mean diameter d50 determined according to ISO 13320:2009 of up to 100.0 μm, and3. water; andii. aggregate, wherein the aggregate has a mean diameter d50 determined according to ISO 13320:2009 and/or according to EN 12620 of greater than 100.0 μm;whereby a core mixture layer is formed, andc. pressing the face mixture layer with the core mixture layer into the mold to form a hydraulically-bonded, directly strippable multilayer panel with at least one face layer and at least one core layer, wherein water contained in the face mixture layer is partially or completely pressed into the core mixture layer