Laminate Board Press Cooling for Smooth Matt Surface Resistance
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Solution Overview
Problem
Existing laminate boards have finishing layers that are not sufficiently smooth, leading to an uncomfortable touch and are vulnerable to external influences such as scratches, acid, and steam, with no method available for producing a laminate with a very smooth and matt surface having good resistances.
Innovation Solution
A method involving the application of a board layer assembly comprising a décor layer and a finishing layer, followed by a main pressing step at a specific temperature and pressure, and a controlled cooling step before releasing pressure, to ensure the finishing layer is smoothed and sealed, resulting in improved properties like low surface roughness, low glossiness, and high resistance to scratching, staining, and steam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a finishing layer is applied on laminate boards using conventional methods, then the board provides basic protection and surface coverage, but the surface is not sufficiently smooth and feels uncomfortable to touch
Solution Approach 1:
The patent applies a cooling step after pressing to reduce the temperature of the finishing layer from processing temperature (typically 80-100°C) to room temperature. This parameter change causes the finishing layer to contract and form a smooth, dense surface structure that eliminates the uncomfortable tactile sensation while maintaining adhesion to the substrate.
Solution Approach 2:
The patent uses a multi-layer composite structure consisting of the substrate (particle board or MDF), intermediate layers (décor layer, balancing layer), and the finishing layer (acrylic coating). This composite structure allows each layer to perform its specific function, with the acrylic finishing layer providing the smooth surface quality that improves touch comfort.
2Reliability
If a finishing layer is applied on laminate boards using conventional methods, then the board provides basic protection, but the laminate remains vulnerable to scratches, acid, and steam
Solution Approach 1:
The cooling step after pressing transforms the finishing layer from a soft, porous state at processing temperature to a hard, dense state at room temperature. This parameter change increases the cross-linking density and reduces free volume, thereby improving resistance to mechanical scratches, chemical acid attack, and thermal steam exposure.
Solution Approach 2:
The acrylic-based finishing layer forms a protective composite barrier over the wood substrate. This composite material system combines the structural support of the wood board with the chemical and mechanical resistance of the acrylic coating, creating a laminate that resists scratches, acid staining, and steam damage.
3Manufacturing precision
If pressing is applied to smooth the finishing layer, then surface quality improves, but releasing pressure too early causes surface defects
Solution Approach 1:
The patent applies a cooling step before releasing the pressing pressure. This preliminary action allows the finishing layer to solidify and stabilize its molecular structure while still under pressure, preventing surface defects such as bubbles, wrinkles, or uneven areas that would occur if pressure were released while the material was still hot and pliable.
Solution Approach 2:
The patent utilizes the phase transition of the acrylic finishing layer from a soft, molten state during pressing to a hard, solid state during cooling. By maintaining pressure during this phase transition and only releasing it after complete solidification, the method ensures defect-free surface quality while achieving the desired smoothness.
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 a laminate board with a smooth, matt surface that is resistant to scratching, staining, and steam, with a nearly closed surface for easy cleaning and high surface quality, as determined by DIN standards.
Implementation Method 1
the board layer assembly is subjected to at least one main pressing step in which the board layer assembly is pressed with a main pressing pressure at a main pressing step temperature
Implementation Method 2
the board layer assembly is pressed with a main pressing pressure
Implementation Method 3
the board layer assembly is subjected to a cooling step in which the board layer assembly is cooled from the main pressing step temperature to a pressure release temperature while keeping the board layer assembly pressed substantially with the main pressing pressure
Data Source
AI summary
The present invention is directed to a method of producing one or more laminate boards, the method comprising the steps: providing at least one board comprising wooden material, producing at least one board layer assembly, subjecting the at least one board layer assembly to at least one main pressing step in which the at least one board layer assembly is pressed with a main pressing pressure at a main pressing step temperature of at least 100 °C, and subjecting the at least one pressed board layer assembly to a cooling step in which the at least one pressed board layer assembly is cooled from the main pressing step temperature to a pressure release temperature of 90 °C or lower while keeping the at least one pressed board layer assembly pressed substantially with the main pressing pressure. Furthermore, the present invention is also directed to a laminate board.