Decorative Laminate Manufacturing Partial Curing Process
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Solution Overview
Problem
Current methods for manufacturing decorative laminates are energy and raw material intensive, and there is a need to reduce these costs while maintaining laminate properties that meet consumer needs.
Innovation Solution
A method involving the application of a first coating to a substrate, placement of an overlaying material, and partial curing of the coatings before final curing in a hot press, using monomers, oligomers, or polymers as coatings and cellulose, plastic, or glass fibers as overlaying materials, with optional additives for decorative or technical properties, and applying a lacquer post-pressing for enhanced adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional resin impregnated overlaying papers are used for manufacturing decorative laminates, then laminate properties meet consumer needs, but energy consumption and raw material usage increase
Solution Approach 1:
The patent applies a polymer coating to the substrate surface and performs partial curing before placing the overlaying paper. This preliminary action allows the resin to be pre-applied and partially set, reducing the amount of resin needed in the final impregnation step and lowering overall energy consumption during manufacturing while still achieving the required laminate properties
Solution Approach 2:
The patent changes the curing parameter by implementing a two-stage curing process: initial partial curing of the polymer coating, then final curing after overlaying paper placement. This parameter change allows for reduced energy consumption in each stage compared to traditional single-stage high-energy curing, while maintaining laminate quality
2Reliability
If traditional resin impregnated overlaying papers are used for manufacturing decorative laminates, then laminate properties meet consumer needs, but raw material cost increases
Solution Approach 1:
The polymer is applied to the substrate surface in advance and partially cured before the overlaying paper is placed. This preliminary application of resin reduces the amount of resin that would otherwise need to be applied through traditional impregnation methods, thereby reducing raw material consumption while still achieving adequate laminate properties
Solution Approach 2:
The patent extracts the resin application step from the traditional impregnation process and separates it into a preliminary coating stage and a final bonding stage. This extraction allows for more efficient resin utilization and reduced overall raw material usage while maintaining the necessary laminate characteristics
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 minimizes energy usage by allowing higher solids content in coatings, reducing solvent content, and minimizing raw material consumption, while ensuring the laminate meets consumer requirements with improved dimensional stability and productivity.
Implementation Method 1
partially curing or drying at least part of the first coating after placement of the overlaying material, and partially curing at least part of the second coating after application of the second coating
Implementation Method 2
curing the polymer and the overlaying material under heat and pressure
Implementation Method 3
curing the polymer and the overlaying material under heat and pressure
Data Source
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AI summary
A method for manufacturing a laminate includes applying a first coating to a surface of a substrate, placing an overlaying material onto the first coating, and thereafter partially curing at least part of the first coating. A second coating may be applied to the overlaying material, and initial partial curing effected after the second coating has been applied to the combination of the first coating and the overlaying material. Typically, the substrate, the first coating, the second coating if applied and the overlaying material are pressed as an assembly in a hot press to form a laminate.