Melamine utensil made from melamine composite material and method of manufacturing the same
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Solution Overview
Problem
Conventional melamine utensils using secondary materials have rough surfaces due to exposed shards, which are prone to peeling and falling off, limiting market growth and consumer demand.
Innovation Solution
A composite material comprising primary melamine powder, secondary melamine shards, and melamine resin glazing powder is used, which is preheated and hot-pressed to form a combination body that adheres to and covers the secondary shards, enhancing structural strength and surface smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If broken pieces of secondary melamine material are mixed with primary melamine powder to form composite material, then novel and decorative effects are provided through visible shapes and colors on the outer surface, but the surface becomes rough and the broken pieces are prone to peeling and falling off
Solution Approach 1:
A binding agent comprising melamine resin powder and water is introduced as an intermediary substance. This binding agent coats the broken pieces of secondary melamine material during mixing, creating a protective layer that bonds the shards to the primary melamine powder matrix. The binding agent acts as a mediator that enables the decorative broken pieces to be integrated into the composite material without causing surface roughness or peeling defects.
2Ease of manufacture
If broken pieces of secondary melamine material are used in the composite material, then the utensil gains decorative appearance with visible shapes and colors, but the structural integrity is compromised due to exposed shards that can peel and fall off upon impact
Solution Approach 1:
The binding agent serves as a structural intermediary that reinforces the composite material. By coating the broken pieces and bonding them to the primary melamine powder, the binding agent creates a unified structure where the decorative shards are mechanically integrated. This prevents peeling and falling off upon impact, thereby maintaining structural integrity while preserving the decorative appearance.
Solution Approach 2:
The invention creates a multi-component composite material system consisting of primary melamine powder, broken pieces of secondary melamine material, and binding agent. This composite structure combines the aesthetic properties of the secondary material shards with the binding properties of the resin, resulting in a material that maintains both decorative appearance and structural strength.
3Device complexity
If conventional hot-pressing process is used without binding agent, then the manufacturing process is simple, but the defect rate increases due to exposed and projecting broken pieces on the outer surface
Solution Approach 1:
The binding agent is mixed with the primary melamine powder and broken pieces before the hot-pressing process. This preliminary action ensures that the broken pieces are pre-coated and bonded to the matrix, preventing them from projecting or peeling during and after hot-pressing. The binding agent is incorporated in advance, so no additional post-processing steps are needed to address surface defects.
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 solution results in a melamine utensil with a smooth surface and improved structural integrity, reducing defects and enhancing market competitiveness.
Implementation Method 1
During the hot-pressing, the primary powder-like melamine material and the melamine resin glazing powder are melted by the hot-pressing to form a combination body
Implementation Method 2
the composite material is preheated and placed into a mold to be produced into a melamine utensil by hot-pressing
Data Source
AI summary
A melamine utensil made from melamine composite material and a method of manufacturing the same are provided. Stir and mix 60-70 weight percentage (wt %) of a primary powder-like melamine material, 20-30 wt % of shards of a secondary melamine material, and 5-15 wt % of melamine resin glazing powder, or 49-59 wt % of the primary powder-like melamine material, 16-26 wt % of shards of the secondary melamine material, 12-22 wt % of pulp, and 6-10 wt % of the melamine resin glazing powder evenly to form a composite material. The composite material is pre-heated and mounted into a mold to produce the melamine utensil by hot pressing. The shards of the secondary melamine material with different shapes, sizes or colors are formed by crushing of the hot-pressed secondary melamine material. During the hot-pressing, the primary melamine material and the melamine resin glazing powder are melted and attached to the secondary melamine material.