Laminate Embossed Back Surface for Bonding

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Solution Overview

Problem

The existing methods for producing laminates result in asymmetrical and irregular surfaces when sanding the back for bonding to a carrier material, leading to moisture penetration and increased adhesive usage, which complicates processing and storage.

Innovation Solution

An embossed structure is created during the laminate production, mimicking the geometry of a ground surface, maintaining the top resin layer as a continuous seal and improving wettability, allowing for reduced adhesive usage and preventing moisture ingress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the back of the laminate is sanded to improve bonding properties, then bonding capability is improved, but the surface becomes irregular and asymmetrical

Engineering Contradiction:

Improvebonding capabilityVSAvoidsurface regularity

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The embossed structure is created during the laminate production process itself, before the bonding step. This preliminary action eliminates the need for subsequent sanding operations, as the bonding-enhancing structure is already in place when the laminate is manufactured

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of removing material (sanding) to create bonding surface irregularities, the invention inverts the approach by adding structure through embossing during production. This builds the bonding-enhancing geometry positively rather than negatively

Inventive Principle:

Principle #13The other way round (Inversion)

2Strength

If sanding is performed to enhance bonding, then adhesive penetration is improved, but moisture penetration increases

Engineering Contradiction:

Improveadhesive bondingVSAvoidmoisture penetration

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The embossed structure creates local variations in surface geometry that enhance adhesive penetration and bonding at specific contact points, while the overall continuous resin layer remains intact to provide global moisture protection

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The laminate structure combines the embossed surface geometry with the continuous resin layer to achieve dual functionality: enhanced bonding through surface irregularity and moisture protection through material continuity

Inventive Principle:

Principle #40Composite materials

3Strength

If excessive adhesive is used to compensate for surface irregularities, then bonding strength is maintained, but processing complexity increases

Engineering Contradiction:

Improvebonding strengthVSAvoidprocessing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The laminate surface structure serves itself by providing bonding enhancement inherent to its geometry. The embossed pattern naturally promotes adhesive penetration and bonding without requiring excessive adhesive application or special processing procedures

Inventive Principle:

Principle #25Self-service

4Strength

If the laminate surface is made asymmetrical through sanding, then bonding is improved, but storage and handling become more difficult

Engineering Contradiction:

Improvebonding capabilityVSAvoidhandling ease

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The bonding-enhancing structure is created during manufacturing before the laminate needs to be handled or stored. This preliminary structuring allows the laminate to maintain its regular external appearance while having optimized bonding surfaces, avoiding handling difficulties

Inventive Principle:

Principle #10Preliminary action

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 embossed structure enhances bonding properties without surface irregularity, maintains the resin layer integrity, and reduces adhesive requirements, ensuring a smooth, impermeable surface for storage and processing.

Implementation Method 1

The supply of heat and pressure causes the resins to flow and then harden

Methodology Applied

Scientific EffectThermal heating: Heating

Implementation Method 2

The supply of heat and pressure causes the resins to flow and then harden

Methodology Applied

Scientific EffectPressure application: Compression

Implementation Method 3

the surface of the core layer arranged opposite the decorative layer having an embossed structure

Methodology Applied

Scientific EffectMechanical embossing: Deformation

Implementation Method 4

maintains the top resin layer as a continuous seal and improving wettability, allowing for reduced adhesive usage and preventing moisture ingress

Methodology Applied

Scientific EffectBarrier protection: Physical Containment

Data Source

PatentEP3119607B1Laminate, pressing means, and method for the production thereof

Publication Date: 2018.02.28 FRITZ EGGER GMBH & CO OG

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AI summary

The invention relates to a laminate for application onto a carrier material, in particular onto a carrier plate, having a resin-impregnated decorative layer (4), and having at least one resin-impregnated core layer (6, 8, 10), wherein the decorative layer (4) and the at least one core layer (6, 8, 10) are suited to be pressed together under high pressure and heat. The technical problem addressed by the invention is that of improving a laminate for application onto a carrier material, in particular onto a carrier plate. This problem is solved in that the layer arranged opposite the decorative layer has an embossed structure substantially corresponding to a structure produced by way of grinding. The invention further relates to a pressing means, and to a method for producing such a laminate.