Method for producing laminate composite materials
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Solution Overview
Problem
Integrating reinforcing textile mat structures based on glass fibers into sandwich-like laminate composite materials based on halogenated polymers, particularly PVC, is challenging, limiting the use of continuous production methods and affecting fire protection requirements in applications like luxury vinyl tile floor coverings.
Innovation Solution
A method involving the production of laminate composite materials with a textile mat structure based on glass fibers, comprising regions of high and low air permeability, applied between two halogenated polymer layers, allowing for lamination under pressure and temperature, and optionally including additional decorative or protective layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcing textile mat structures based on glass fibers are integrated into sandwich-like laminate composite materials based on halogenated polymers, then mechanical properties and fire protection are improved, but the complexity of production and difficulty of integration increase
Solution Approach 1:
The textile mat structure is segmented into regions with high air permeability and regions with low air permeability, allowing different functional zones within the same reinforcement layer. This segmentation enables optimized bonding in low permeability regions while maintaining drainage and ventilation capabilities in high permeability regions, resolving the contradiction between integration difficulty and production complexity
Solution Approach 2:
Different regions of the textile mat structure are assigned different air permeability properties to fulfill different functions: low air permeability regions provide strong bonding with the halogenated polymer layers for mechanical strength, while high air permeability regions provide drainage and ventilation pathways. This local differentiation resolves the contradiction by allowing the same material structure to serve multiple functions simultaneously
2Productivity
If continuous production methods are used for manufacturing laminate composite materials, then productivity is improved, but the ease of manufacture decreases due to integration challenges
Solution Approach 1:
The patent enables continuous production methods by designing a textile mat structure that can be continuously manufactured and integrated into the laminate composite material production line. The consistent structure with defined high and low air permeability regions allows for uninterrupted processing, resolving the contradiction between productivity improvement and ease of manufacture
Solution Approach 2:
The air permeability parameter of the textile mat structure is specifically optimized to enable continuous production. By controlling the air permeability characteristics, the material allows for continuous bonding processes while maintaining the necessary structural integrity, thus improving productivity without sacrificing ease of manufacture
3Object-affected harmful factors
If regions with high air permeability are introduced into the textile mat structure, then fire protection and drainage capabilities are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The textile mat structure incorporates regions with high air permeability that function as porous structures for drainage and fire protection. These porous regions allow water and smoke to pass through while maintaining structural integrity, resolving the contradiction between improved fire protection and manufacturing precision requirements
Solution Approach 2:
The textile mat is segmented into distinct high air permeability and low air permeability regions with defined geometries. This segmentation allows for controlled placement of functional zones, ensuring that the manufacturing precision requirements are met while achieving the desired fire protection and drainage capabilities
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 enables the production of sandwich-like laminate composite materials with enhanced mechanical properties, improved fire protection, and cost-effective, continuous processing, suitable for various applications including luxury vinyl tiles and wall or ceiling panels.
Implementation Method 1
the fibre nonwoven comprises regions with high air permeability and regions with low air permeability
Implementation Method 2
laminating the structure obtained in accordance with step (iii) by applying pressure and/or temperature
Data Source
AI summary
A method for producing laminate composite materials, as well as the laminate composite materials produced by this method and their use are described. The laminate composite materials are sandwich-like in construction and based on halogenated polymers and comprise a first laminar structure formed from halogenated polymer and a second laminar structure formed from halogenated polymer as well as at least one textile mat structure based on inorganic fibres, which is disposed between the first and the second laminar structure. The textile mat structure based on inorganic fibres comprises regions with high air permeability and regions with low air permeability, through which the two laminar structures formed from halogenated polymer are monolithically bonded together.