Layered Polymer Carrier Extrusion for Smooth Decorative Panels
Find Innovative SolutionsGenerate Solutions
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 carrier material, but significant waste heat loss occurs and production efficiency is reduced
Solution Approach 1:
The patent converts the harmful waste heat from the pressing process into a beneficial resource by using it for preheating the polymer granulate before it enters the press. The cooling water that absorbs heat during the cooling phase is then used to preheat subsequent batches of granulate, creating a heat recovery system that eliminates waste heat loss and improves energy efficiency.
Solution Approach 2:
The patent applies preliminary heating to the polymer granulate using the recovered heat from the pressing and cooling processes before the granulate enters the press. This preheating action reduces the energy required during the actual pressing operation and improves overall process efficiency by preparing the material in advance.
2Speed
If high temperature gradient is applied for cooling to achieve acceptable belt speeds, then production speed improves, but waste heat losses increase significantly
Solution Approach 1:
The patent captures the waste heat that would otherwise be lost during high-speed cooling and uses it to preheat subsequent batches of polymer granulate. The cooling water circulating through the press absorbs the heat during rapid cooling, and this heated water is then routed to preheat the granulate feed, converting the harmful heat loss into a useful preheating function that enables high belt speeds without net energy penalty.
3Stability of the object's composition
If air is pressed out of the carrier material slowly during cooling, then material density improves, but production time increases and belt speeds must be reduced
Solution Approach 1:
The patent applies preliminary heating to the polymer granulate before pressing, which reduces the viscosity and improves the flow characteristics of the material. This preliminary thermal preparation allows air to be evacuated more efficiently during pressing and cooling, achieving good material density without requiring excessively slow processing speeds, thereby maintaining higher productivity.
4Manufacturing precision
If multiple elaborate method steps are used to apply decorations, top layers and wear layers, then panel quality improves, but process complexity and production time increase
Solution Approach 1:
The patent merges the pressing, cooling, and decoration application operations into a single integrated belt press system. The decorative layers are applied to the carrier material while it passes through the press, and the same pressing action that consolidates the carrier material also bonds the decorative layers. This combination eliminates separate elaboration and bonding steps, reducing process complexity while maintaining quality.
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, non-conformance, and environmental footprint while allowing easy application of further layers.
Implementation Method 1
providing a first molten polymer mass and a second molten polymer mass; extruding the molten polymer masses
Implementation Method 2
each polymer mass is extruded by a separate extruder, wherein the molten polymer masses are layered on top of each other
Implementation Method 3
controlled cooling leads to a solidification or crystallization of the carrier material
Implementation Method 4
the material can be pressed and formed into the shape of a carrier
Implementation Method 5
heat is transferred from above and below by contact with the press. Another disadvantage for cooling is that the heat must pass through the glass-fiber-reinforced Teflon belt. Only then the heat transfer takes place through heat conduction into the granulate bed or the carrier material
Implementation Method 6
controlled cooling leads to a solidification or crystallization of the carrier material
Data Source
AI summary
A method for producing a decorated wall or floor panel comprises: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; andd) 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.