Modified Resin Layer for Wood-Based Sheet Tactile Properties
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Solution Overview
Problem
Current wood-based sheets struggle to achieve realistic tactile and visual imitations of natural surfaces, particularly in terms of tactile properties, thermal conductivity, and acoustic properties, while also facing limitations with the use of PVC in luxury vinyl tiles and inferior properties of melamine-free polymer coatings.
Innovation Solution
A support material with a modified resin layer composed of formaldehyde resin, polyacrylates, polyepoxides, polyurethanes, and silane-containing compounds, which forms a three-component system for enhanced tactile and visual realism, including the use of impregnated paper layers and laminates for improved flexibility and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional melamine coatings are used on wood-based sheets, then good property profile and visual imitation are achieved, but tactile properties and thermal conductivity are insufficient
Solution Approach 1:
The patent applies composite materials by combining melamine resin with flexible polymers (polyurethane, polyacrylate, polyester) and fillers (cellulose fibers, hollow spheres) to create a multi-component coating system. This composite structure enables simultaneous achievement of visual imitation quality and improved tactile properties, resolving the contradiction between conventional melamine coatings and desired tactile performance.
Solution Approach 2:
The patent introduces local quality by creating a resin layer with specific local properties (flexibility, resilience) that differs from the conventional uniform melamine coating. The modified resin layer provides enhanced tactile properties in the surface region while maintaining the overall structural integrity and visual appearance of the wood-based sheet.
2Object-affected harmful factors
If flexible laminates are applied onto support sheets to improve tactile properties, then realistic imitation of natural surfaces is achieved, but processing complexity and cost increase
Solution Approach 1:
The patent merges the flexible laminate function directly into the support sheet by incorporating flexible polymers and fillers into the melamine resin coating applied during the standard production process. This integration eliminates the need for separate lamination steps, reducing processing complexity while maintaining improved tactile properties.
Solution Approach 2:
The patent applies parameter changes by modifying the resin composition parameters (adding flexible polymers and fillers) to transform the conventional rigid melamine coating into a flexible, resilient surface layer. This chemical parameter modification achieves laminate-like properties without requiring physical lamination processes.
3Object-affected harmful factors
If LVT (luxury vinyl tiles) are used to obtain flexible surfaces, then realistic tactile imitation is achieved, but PVC content and plasticizer issues arise
Solution Approach 1:
The patent extracts and eliminates PVC from the formulation by replacing it with alternative flexible polymers such as polyurethane, polyacrylate, and polyester. This substitution removes the harmful PVC and plasticizer content while preserving the flexible surface properties and realistic tactile imitation capabilities.
Solution Approach 2:
The patent employs cost-effective, environmentally friendly polymers (polyurethane, polyacrylate) that serve as temporary or disposable alternatives to PVC. These polymers provide the necessary flexibility and tactile properties without the long-term environmental and health issues associated with PVC and plasticizers.
4Object-affected harmful factors
If fillers are incorporated into melamine-resin surfaces to improve tactile properties, then resilience is enhanced, but surface hardness and durability are reduced
Solution Approach 1:
The patent optimizes filler parameters (type, size, concentration) to achieve the desired balance between tactile properties and surface hardness. By carefully controlling filler content and selecting appropriate filler materials, the resin layer achieves enhanced resilience while maintaining sufficient surface hardness and durability for practical applications.
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 provides robust, resilient surfaces with pleasant tactile properties and realistic imitations of natural surfaces, offering improved thermal conductivity, hardness, and acoustic performance, while avoiding the drawbacks of PVC and melamine-free coatings.
Implementation Method 1
at least one silane-containing compound of the general formula RaSiX(4-a) and/or hydrolysis product thereof
Data Source
AI summary
A carrier material has a resin layer arranged on a side of the carrier material. The resin layer includes a formaldehyde resin, a polymer selected from a group containing polyacrylates, polyepoxides, polyesters, polyurethanes, and long-chain silanols, and at least one silane-containing compound of general formula (I), Ra SiX(4-a), and/or the hydrolysis product thereof, where X is H, OH, or a hydrolyzable residue selected from the group comprising halogen, alkoxy, carboxy, amino, monoalkylamino or dialkylamino, aryloxy, acyloxy, alkylcarbonyl; R is a non-hydrolyzable organic residue R selected from the group comprising alkyl, aryl, alkenyl, substituted and unsubstituted alkynyl, cycloalkyl, which can be interrupted by —O— or —NH—; and where R can have a functional group Q selected from a group containing a hydroxy, ether, amino, monoalkylamino, dialkylamino, anilino, amide, carboxy, mercapto, alkoxy, aldehyde, alkylcarbonyl, epoxide, alkenyl, alkynyl, acryl, acryloxy, methacryl, methacryloxy, cyano, and isocyano group, and a is 0-3.