Laminate Board Interim Sheet Pressing for Faster Durable Production
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Solution Overview
Problem
Existing laminate board production methods, such as HPL and DPL, are either laborious and time-consuming or result in less durable products, lacking flexibility and efficiency.
Innovation Solution
A two-step method involving pressing thermosetting resin-impregnated sheet materials at controlled temperatures and pressures to form an interim sheet, which is then combined with other layers to create a laminate board, allowing for customizable designs and reduced processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the HPL process is used to produce laminate boards, then high-quality and durable laminate boards are achieved, but the process becomes laborious and time-consuming (6-7 days)
Solution Approach 1:
The HPL process is divided into two distinct pressing stages: a first pressing stage that forms an interim sheet with partially cured resin, and a second pressing stage that completes the lamination and curing. This segmentation allows the complex process to be broken down into manageable phases, reducing total production time while maintaining quality through controlled intermediate states.
Solution Approach 2:
The first pressing stage performs preliminary actions by forming an interim sheet with partially cured resin before the final lamination. This preliminary formation of the sheet structure with partially cured resin allows subsequent layers to be added and then all layers to be pressed together in a second stage, reducing the total time required compared to a single prolonged pressing operation.
2Loss of time
If the DPL process is used to produce laminate boards, then production time is reduced and cost is lowered, but the laminate boards become less durable and more prone to scratches and dents
Solution Approach 1:
The invention changes the pressure and temperature parameters during the two pressing stages. The first stage uses moderate pressure and temperature to form an interim sheet with partially cured resin, while the second stage uses higher pressure and temperature to complete the lamination and curing. This parameter optimization ensures both speed and durability by controlling the curing progression.
Solution Approach 2:
The invention creates a composite structure with multiple layers (substrate, interim sheet with partially cured resin, decorative sheet, overlay sheet) that are pressed together. This composite approach combines the benefits of rapid production from the DPL method with the durability of HPL by ensuring complete curing through the two-stage pressing process, resulting in a laminate board that is both fast to produce and resistant to scratches and dents.
3Strength
If thermosetting resins are fully cured during pressing, then strong bonding is achieved, but the resins cannot flow again when heated for subsequent processing
Solution Approach 1:
The invention employs periodic action by alternating between two pressing stages with different temperature and pressure conditions. The first stage bonds layers with partially cured resin, then the sheet is removed and cooled. The second stage re-heats the interim sheet to allow resin flow and complete bonding. This periodic cycling of heating and cooling, bonding and re-bonding, achieves both initial bonding strength and subsequent processing flexibility.
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 produces durable laminate boards with enhanced flexibility and efficiency, reducing production time to 4 days or less while maintaining high quality and durability, with the option for custom designs and reduced material usage.
Implementation Method 1
pressing the first and second sheet materials together, preferably at a temperature of between 60° C. and 135° C., preferably between 60° C. and 115° C., preferably for between 40 and 130 minutes, such that the first and second thermosetting resins become liquid
Implementation Method 2
pressing with a first sufficient pressure such that the first and second sheet materials fuse to form an interim sheet without fully curing the first and second thermosetting resins such that the first and second thermosetting resins can flow again when heated
Data Source
AI summary
The present invention relates to a method for producing an interim sheet, the method comprising the steps of:k) providing at least a first sheet material impregnated with a first thermosetting resin, and a second sheet material impregnated with a second thermosetting resin; and,l) pressing the first and second sheet materials together, at a temperature of between 60° C. and 115° C., for between 40 and 130 minutes, such that the first and second thermosetting resins become liquid, and pressing with a first sufficient pressure such that the first and second sheet materials fuse to form an interim sheet without fully curing the first and second thermosetting resins such that the first and second thermosetting resins can flow again when heated.