Inline Coated Panel Lamination on Extruded Synthetic Substrates
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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 absorption and poor sound insulation.
Innovation Solution
A continuous method for manufacturing coated panels involving the inline adherence of a thermosetting resin-based top layer to a synthetic substrate material, such as a solid plastic composite, using a polymeric material and adhesive, which eliminates the need for discrete press operations and enhances mechanical properties and sound absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a discontinuous manufacturing method with separate pressing operations is used, then the manufacturing precision of the coated panel can be maintained, but the productivity is reduced and manufacturing cost increases
Solution Approach 1:
The patent combines the extrusion of synthetic substrate material and the adhering of the top layer material into a single continuous inline process. The extrusion device and adhering device are integrated such that the top layer is applied to the substrate material while it is being extruded, eliminating the need for separate pressing operations and discontinuous manufacturing steps.
Solution Approach 2:
The patent implements a continuous manufacturing process where the extrusion and adhering operations occur continuously in an inline manner. The substrate material is extruded continuously and the top layer material is adhered to it in a continuous stream, maintaining uninterrupted production flow and eliminating idle time between operations.
2Reliability
If wood-based materials are used for the panel core, then the manufacturing cost is reduced, but the reliability deteriorates due to water absorption and panel damage
Solution Approach 1:
The patent uses a composite structure consisting of a synthetic substrate material (such as plastic composite) as the core and a thermosetting resin-based top layer material. This composite construction provides water resistance and durability while maintaining manufacturability through continuous extrusion and adhering processes.
3Ease of manufacture
If a continuous inline adhering process is used, then the productivity is improved and manufacturing cost is reduced, but the device complexity increases
Solution Approach 1:
The patent merges the extrusion device and adhering device into an integrated inline system. The extrusion device extrudes the synthetic substrate material while the adhering device simultaneously applies and bonds the top layer material, combining multiple functions into a unified continuous process that reduces overall manufacturing complexity despite the integration requirement.
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 efficient, cost-effective, and durable coated panel with improved mechanical properties and sound absorption, suitable for use in water-resistant and sound-insulating applications.
Implementation Method 1
adhering, in a continuous manner, said top layer material to said substrate material by means of at least said adhesive material
Data Source
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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).