Material Board Pressing with Two-Stage Binder Curing
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Solution Overview
Problem
Existing long and large press systems for producing material boards are complex, prone to failure, and require high investment and operational costs, especially when using advanced binders like aminophenol-based and bio-based adhesives, with operational complexity and maintenance needing specialized expertise.
Innovation Solution
A continuous method using a double belt press for partial curing of cover layers and an injection press for full curing of the middle layer with tempered fluids, reducing the need for extensive steel belts and improving production speed and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If long and large press systems are used for producing material boards, then production quality can be maintained, but device complexity and operational complexity increase significantly
Solution Approach 1:
The press system is divided into two independent units: a double belt press for partial curing of cover layers and an injection press for full curing of the middle layer. This segmentation reduces the complexity of each individual unit while maintaining overall production quality through coordinated operation of both presses.
2Manufacturing precision
If long and large press systems are used for producing material boards, then production quality can be maintained, but investment costs and operational costs increase
Solution Approach 1:
By splitting the press function into two separate presses (double belt press and injection press), the investment cost for each unit is reduced compared to a single large press system. The modular design allows for more economical construction and operation while achieving the same production quality.
3Manufacturing precision
If traditional press systems are used, then complete curing can be achieved, but production speed decreases and operational complexity increases
Solution Approach 1:
The double belt press performs partial curing of the cover layers without completing the curing of the entire press mat. This partial action allows for faster processing of the surface layers while the injection press subsequently completes the curing of the middle layer, overall increasing production speed while maintaining curing completeness.
4Object-affected harmful factors
If advanced binders like aminophenol-based and bio-based adhesives are used, then environmental compatibility improves, but setting behavior becomes more complex requiring specialized operational expertise
Solution Approach 1:
The curing process is segmented into two stages with different presses, allowing each press to be optimized for specific binder types. The double belt press handles cover layer curing with controlled heat transfer, while the injection press handles middle layer curing with fluid injection, simplifying operational parameters for advanced binders.
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 approach significantly reduces operational complexity and costs while maintaining high-quality production, allowing for the use of diverse binders and enhancing production efficiency by partial curing in the double belt press and full curing in the injection press.
Implementation Method 1
the press mat is compressed continuously in a double belt press with steel belts which are warmer than the press mat and is heated by thermal conduction
Implementation Method 2
the uncured parts of the press mat, in particular the uncured middle layer, are heated and cured in a downstream injection press by introducing tempered fluids to a temperature above the curing temperature of the binder
Data Source
AI summary
A method and a plant for the production of material boards from at least one material which is spread to form a press mat and mixed with at least one binder curable by heat and/or pressure. The press mat is compressed in a double belt press with steel belts warmer than the press mat, and is heated by heat conduction. At least one cover layer resting against a steel belt is heated to a temperature above the curing temperature of the binder and cured at least partially. The uncured parts of the press mat are heated and cured in a downstream injection press by introducing tempered fluids to a temperature above the curing temperature of the binder. Fluids are introduced into or through the press mat through one or both cover layers. Also provided are a material board produced by a method and/or in such a plant.