Layered Polymer Panel Extrusion for Smooth Decorative Surfaces
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Solution Overview
Problem
Existing methods for producing decorated wall or floor panels are inefficient, requiring multiple elaborate steps, result in significant waste heat loss, and produce panels with uneven surfaces and poor decorative properties, leading to high non-conformance rates and environmental impact.
Innovation Solution
A method involving the extrusion and calibration of layered molten polymer masses using separate extruders, forming a plate-shaped carrier with a carrier layer and sealable layer, followed by calibration with adjustable roller gaps to create a smooth, defect-free surface for efficient decoration application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If belt pressing process with contact heating and cooling is used, then panels can be produced with solidified carrier material, but waste heat losses are considerable and cooling process is slow
Solution Approach 1:
The invention extracts the molten polymer mass from the belt pressing process and directly extrudes it through a die to form the carrier plate. This eliminates the need for contact heating and cooling belts, allowing waste heat to be recovered rather than lost, while significantly accelerating the cooling process through direct water cooling of the extruded plate.
Solution Approach 2:
The extruded molten polymer mass serves multiple functions: it forms the carrier plate structure, contains the decorative layer, and enables efficient heat transfer for cooling. The single extrusion process combines forming and cooling functions that were previously separated into multiple belt pressing and cooling steps.
2Productivity
If multiple elaborate method steps are used to apply and bond layers, then decorated panels can be produced, but production efficiency is reduced and energy consumption increases
Solution Approach 1:
The invention merges the carrier plate formation and decorative layer application into a single extrusion process. The decorative layer is incorporated into the extruded molten polymer mass before calibration, eliminating separate bonding steps and reducing both production time and energy consumption while maintaining panel quality.
3Speed
If high temperature gradient is applied for cooling to achieve acceptable belt speeds, then production speed can be maintained, but waste heat losses increase
Solution Approach 1:
The invention converts the previously harmful waste heat into a beneficial resource by implementing a heat recovery system. The thermal energy from the extruded molten polymer mass is captured and reused, allowing efficient cooling at high production speeds without the waste heat losses that plagued the belt pressing method.
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
Enables high-quality panels with improved decorative properties and dimensional stability, reducing production time and waste, increasing throughput, and allowing for easy application of further layers while minimizing environmental footprint.
Implementation Method 1
extruding the molten polymer masses, wherein in particular each polymer mass is extruded by a separate extruder
Implementation Method 2
calibrating the layered molten polymer masses to form a plate-shaped carrier
Data Source
AI summary
The present disclosure relates to a method for producing a decorated wall or floor panel, comprising the method steps:a) providing a first molten polymer mass and a second molten polymer mass;b) extruding the molten polymer masses, wherein in particular each polymer mass is extruded by a separate extruder, wherein the molten polymer masses are layered on top of each other;c) expelling the layered molten polymer masses through a die;d) calibrating the layered molten polymer masses in order to form a plate-shaped carrier comprising at least one carrier layer comprising the first polymer mass and a sealable layer contacting the carrier layer and comprising the second polymer mass. Furthermore, the disclosure relates to plate-shaped carriers and decorative panels produced in this way, and to a device for carrying out the method.