Method for manufacturing a plate shaped product and plate shaped product manufactured thereby
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing plate-shaped products, such as floor products, face high capital costs and produce products with poor dimensional stability and shrinkage issues due to the need for multiple calender lines and laminating processes, resulting in harder but less flexible products.
Innovation Solution
A method combining multiple coating and calendering processes to create intermediate products, where a carrier, plastic printing, and decorative layers are coated, and then laminated with calendered plastic layers, offering improved dimensional stability and stiffness through mechanical embossing and thermic cross-linking, and potentially including additional layers for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple calender lines and laminating processes are used, then the product achieves sufficient stiffness and dimensional stability, but the capital cost increases significantly
Solution Approach 1:
The manufacturing process is divided into two independent stages: first producing a printed intermediate product with carrier, printing layer, and decorative layer; then producing a separate protective layer intermediate product. These segmented intermediate products are manufactured using simpler, less expensive equipment and subsequently combined through lamination to achieve the final product with sufficient dimensional stability.
Solution Approach 2:
The carrier, printing layer, and decorative layer are prepared in advance as a printed intermediate product, and the protective layer is prepared separately as another intermediate product. This preliminary preparation allows each layer to be optimized independently and combined later, avoiding the need for complex multi-line calendering equipment.
2Strength
If multiple calender lines and laminating processes are used, then the product achieves sufficient stiffness, but the product becomes harder and less flexible
Solution Approach 1:
Different regions of the final product have different properties: the carrier and printing layers provide flexibility and design, while the separate protective layer provides stiffness and durability. By applying local quality principles, each layer performs its specific function optimally without compromising the overall balance between flexibility and stiffness.
3Stability of the object's composition
If multiple calender lines and laminating processes are used, then the product achieves sufficient dimensional stability, but shrinkage phenomena occur
Solution Approach 1:
By segmenting the manufacturing process into separate intermediate product productions followed by lamination, each intermediate product can be cured and stabilized independently before final assembly. This reduces the cumulative shrinkage that occurs in continuous multi-line calendering processes where layers are bonded under stress.
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 method achieves a balance between flexibility and stiffness, providing excellent dimensional stability and reducing shrinkage, while minimizing capital costs by integrating the advantages of both coating and calendering processes.
Implementation Method 1
a first intermediate product is produced which comprises at least, successively, a backing layer, a carrier, a printing layer, a decorative layer and a protective layer
Implementation Method 2
several continuous sheet or foil shaped layers are produced by calendering
Implementation Method 3
combining the first and second intermediate products by laminating, such that the second intermediate product is attached to the first intermediate product
Implementation Method 4
During a subsequent gelling process the plastisols gel and the separate layers are interconnected
Implementation Method 5
The plasticizers act as softeners for keeping the final floor product flexible
Data Source
AI summary
A method is presented for manufacturing a plate shaped product, comprising the steps of manufacturing a first intermediate product which comprises at least, successively, a carrier, a plastic printing layer, a decorative print layer and a plastic protective layer, by using a multiple coating process, manufacturing a second intermediate product which comprises at least one plastic layer, by using at least a calendering process, and combining the first and second intermediate products by laminating, such that the second intermediate product is attached to the first intermediate product. Further a plate shaped product is provided which is manufactured using said method.