Multilayer composite
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Solution Overview
Problem
Existing multi-layer composite bodies for furniture construction face challenges such as the need for flat and planar wood or wood substitutes, damage to lacquer layers during gluing, lack of color stability, and irregular surfaces with poor gloss and haze qualities, especially when using chipboard or MDF boards.
Innovation Solution
A multi-layer composite body design featuring a spacer element made of fleece with specific material composition and thickness, cohesively connected to a base plate and polymeric laminate via reactive hot melt adhesive and dispersion adhesives, allowing for cost-effective production with optimal surface quality and high-gloss optics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a multilayer composite is formed by sequentially depositing multiple layers of material, then the composite can provide multiple functions (e.g., optical control, barrier properties, conductivity), but the manufacturing complexity and time increase significantly
Solution Approach 1:
The patent divides the composite material into discrete functional layers, where each layer performs a specific function (e.g., barrier layer, conductive layer, optical layer). This segmentation allows independent optimization and manufacturing of each layer, reducing overall manufacturing complexity while maintaining functional versatility.
Solution Approach 2:
The patent combines multiple materials with different properties into a single composite structure, where each material contributes specific functionality. This approach enables the composite to achieve multiple functions simultaneously without requiring separate components, thereby reducing manufacturing steps and complexity.
2Ease of manufacture
If conventional separate components are used to achieve multiple functions, then manufacturing is simpler, but the final product has larger dimensions and less integration
Solution Approach 1:
The patent merges multiple functional components into a single integrated multilayer composite structure. By combining barrier, conductive, optical, and other functions into one compact composite, the patent reduces the overall volume and eliminates the need for separate components, while maintaining manufacturing simplicity through standardized deposition processes.
Solution Approach 2:
The patent transitions from three-dimensional separate components to a two-dimensional layered composite structure. This dimensional change allows multiple functions to be stacked in layers rather than requiring separate spatial components, thereby reducing the overall volume while maintaining manufacturing ease through sequential deposition.
3Reliability
If thick layers are deposited to ensure adequate coverage and functionality, then functional performance improves, but the total thickness and manufacturing time increase
Solution Approach 1:
The patent applies different material compositions and thicknesses to different layers based on their specific functional requirements. Each layer is optimized locally with the appropriate thickness and material properties needed for its specific function, rather than using uniform thick layers throughout, thereby achieving adequate coverage and functionality with reduced total thickness.
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 enables the production of multi-layer composite bodies with high gloss and haze values, long and short wave values within optimal ranges, ensuring a sophisticated and flat appearance, while being economical and suitable for various decors and glass optics, and capable of withstanding manufacturing-related tolerances.
Implementation Method 1
The spacer element is firmly bonded to the base plate. This ensures the strength and rigidity of the multilayer composite body
Implementation Method 2
the base plate, the polymer laminate, the carrier element, and the spacer element are integrally bonded to one another via at least one bonding layer
Data Source
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AI summary
The invention relates to a multilayer composite having - a base panel, designed preferably in the form of an HDF or MDF panel, - a polymer laminate, which is applied to the base panel and has preferably at least one layer, - and at least one connecting layer between the base panel and the polymer laminate, the multilayer composite being distinguished in that, on at least part of the side located opposite the lower layer of the polymer laminate, the base panel has a spacer element, connected to one another via at least one connecting layer.