Multilayer Curtain Coating for Laminate Manufacturing
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Solution Overview
Problem
Existing methods for manufacturing laminate products require multiple process steps and separate coating stations for applying multiple liquid layers, leading to potential air inclusion and disruption of layer structure during the manufacturing process.
Innovation Solution
The method involves applying two or more uncured liquid layers on a substrate using a curtain coating process, ensuring the layers do not mix or smear when passed between rotating guide rollers, and subsequently curing them to minimize air inclusion and maintain layer structure, using a die with parallel outlet openings to form a multilayer liquid film and applying actinic radiation for cross-linking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple liquid layers are applied separately in separate process steps using separate coating stations, then each layer can be applied with precision, but the number of process steps increases and air inclusion occurs between layers
Solution Approach 1:
The patent combines multiple coating operations into a single coating station by applying multiple liquid layers simultaneously through a multi-layer curtain coating process. The coating head delivers 2-3 different liquid layers in one continuous operation, eliminating the need for separate coating stations and reducing air inclusion between layers while maintaining manufacturing precision.
Solution Approach 2:
The patent implements continuous application of multiple liquid layers in a single uninterrupted process step. The substrate passes through the coating station once, receiving all liquid layers continuously without stopping or repositioning, which maintains layer integrity and eliminates air pockets that would form during discrete coating operations.
2Productivity
If multiple liquid layers are applied simultaneously in a single process step, then the number of process steps is reduced, but the layers may mix or smear during passage between guide rollers
Solution Approach 1:
The patent carefully controls the viscosity parameters of the liquid layers to prevent mixing. By formulating the liquid layers with appropriate viscosity ranges and ensuring the substrate moves at controlled speeds through the coating station, the layers remain distinct during passage between guide rollers while still being applied simultaneously, thus maintaining layer structure integrity.
3Stability of the object's composition
If liquid layers are applied and then cured immediately, then the layer structure is stabilised, but air inclusion occurs between layers during the process
Solution Approach 1:
The patent applies preliminary stabilizing measures during the simultaneous coating process. The liquid layers are applied with controlled viscosity and thickness in a specific sequence, and the substrate is guided through the coating station in a way that prevents air entrapment before curing begins, thus stabilizing the layer structure without air inclusion.
4Object-affected harmful factors
If separate coating stations are used for each liquid layer, then air inclusion is minimised, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple coating stations into a single integrated coating head that delivers multiple liquid layers simultaneously. This consolidation reduces device complexity and eliminates air inclusion between layers that would occur during sequential coating operations, while maintaining the ability to apply different liquid layers with distinct properties.
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 reduces the number of process steps, minimizes air inclusion, and maintains the layer structure, enabling the production of high-quality laminates with specific properties and improved matting and scratch resistance.
Implementation Method 1
the decorative layer being exposed to a high-energy radiation and thereby being cross-linked and/or polymerized
Data Source
AI summary
The present invention relates to a method for manufacturing a laminate product by assembling two substrates provided with liquid coating layers by passing said substrates between two rotating guide rollers. An object of the present invention is to provide a method for manufacturing a laminate product in which the number of process steps for applying two or more liquid layers is minimised. Another object of the present invention is to provide a method for manufacturing a laminate product in which the inclusion of air between the individual layers is minimised.