Low-Tension Cover Layer for Laminate Materials
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current laminate floor production methods require significant amounts of paper and resin, leading to high costs and mechanical stress compensation issues, without effectively reducing material properties.
Innovation Solution
A low-tension top layer for laminate materials comprising a mixture of amino resin and polyvinyl alcohol, where polyvinyl alcohol constitutes 5-10% of the resin, allowing for reduced paper and resin usage by spatially replacing aminoplast resin, thereby minimizing mechanical stress and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If polyvinyl alcohol is used as an additive in small amounts (as disclosed in DE 10 2004 036664 A1), then the laminate material can be produced with standard materials, but the mechanical stress compensation is insufficient and paper/resin savings are limited
Solution Approach 1:
The patent changes the parameter of polyvinyl alcohol content from trace additive levels (as in prior art) to a specific range of 5-10% by weight of the resin mixture. This parameter change transforms the cover layer's mechanical properties, creating low tensile properties that enable both material savings and effective stress compensation. The specific concentration range is critical to achieving the desired balance between reduced material usage and maintained structural reliability.
Solution Approach 2:
The patent creates a composite resin system combining amino resin with polyvinyl alcohol in a specific ratio (5-10% PVA by weight). This composite material exhibits synergistic properties where the PVA modification reduces the overall tensile strength of the cover layer while maintaining adhesion and protective functions. The composite approach allows the cover layer to act as an effective stress compensation system, enabling reduction of the balancing layer materials.
2Object-generated harmful factors
If standard amino resin impregnation is used (as disclosed in GB 855 536), then the laminate material achieves adequate adhesion and protection, but the formaldehyde content is high and production costs are increased
Solution Approach 1:
The patent modifies the chemical composition parameters of the resin system by incorporating polyvinyl alcohol at 5-10% by weight of the total resin. This chemical substitution reduces the proportion of formaldehyde-releasing amino resins while maintaining the necessary adhesion and protective properties through the composite effect. The PVA component provides alternative bonding mechanisms that reduce reliance on formaldehyde-based crosslinking.
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 low-tension top layer reduces the weight and resin usage in laminate materials, maintaining product properties while saving costs and reducing formaldehyde usage, with improved abrasion resistance and surface integrity.
Implementation Method 1
the use of the water-soluble or water-dispersible plastic makes it possible to spatially replace the aminoplast resin in the impregnated decorative paper or overlay paper and thus to reduce the number of individual condensation points
Data Source
AI summary
The present invention relates to a low-tension cover layer which is intended for a laminate material and comprises a resin-impregnated decorative paper with or without printing or a resin-impregnated overlay paper, or a combination of the two, wherein the resin comprises in each case a mixture of at least one aminoplast and at least one water-soluble or water-dispersible plastics material selected from the group made up of polyvinyl resin, polyvinyl acetate and polyvinyl alcohol. The invention also relates to the use of the low-tension cover layer according to the invention for constructing a laminate material with corresponding counter-tension.