Non-flammable Laminate Thickness Reduction
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Solution Overview
Problem
Existing decorative laminates for building materials face challenges in achieving a thin profile while meeting fire protection requirements, particularly for fire protection class A1, as they often have high overall thickness and weight.
Innovation Solution
A laminate is produced by combining a non-flammable glass fiber fleece or quartz fiber non-woven fabric impregnated with synthetic resin with a decorative paper impregnated with melamine-formaldehyde resin, using specific fillers and processing methods to achieve a low overall thickness and weight while enhancing fire resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional flame-retardant panel structure is used to meet fire protection class A1, then fire protection requirements are satisfied, but the overall thickness becomes 5 mm or more
Solution Approach 1:
The patent uses a composite structure combining a nonwoven fabric carrier layer impregnated with phenolic resin and aluminum hydroxide/magnesium hydroxide, together with a decorative paper layer impregnated with melamine resin. This composite material approach achieves fire protection class A1 with a total thickness of only 0.6-1.2 mm, dramatically reducing the thickness compared to traditional flame-retardant panels while maintaining reliable fire protection.
2Reliability
If traditional flame-retardant decorative panels are used to ensure fire safety, then fire protection is achieved, but the overall weight increases
Solution Approach 1:
The patent changes the material parameters by using lightweight nonwoven fabric carriers with specific basis weights (30-150 g/m²) and optimizing the content of fire-retardant additives (aluminum hydroxide 20-40 parts, magnesium hydroxide 20-40 parts per 100 parts resin). This parameter optimization achieves fire protection class A1 while keeping the panel weight low, suitable for decorative applications where weight matters.
3Reliability
If multiple layers are added to improve fire protection and wear resistance, then fire protection requirements are met, but the overall thickness increases
Solution Approach 1:
The patent merges multiple functions into a single integrated decorative layer structure. The decorative paper is impregnated with melamine resin (providing surface hardness and wear resistance) and contains fire-retardant additives (achieving fire protection class A1). This merging of fire protection, decoration, and wear resistance functions into one layer eliminates the need for separate fire-retardant layers, achieving all requirements with a total thickness of only 0.6-1.2 mm.
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 laminate achieves a total thickness of less than 2.2 mm and a reduced calorific value, meeting fire protection standards with improved fire behavior and stability, and can be tailored for various applications by adjusting the number and weight of decorative paper layers.
Implementation Method 1
the synthetic resin (3) impregnated in the carrier material layer (2) and the melamine-formaldehyde resin (6) impregnated in the decorative material layer (5) were mixed
Implementation Method 2
pressed to form a composite in such a way that the laminate resulting from the pressing has a total thickness of less than 2.2 mm
Implementation Method 3
a non-flammable composite can be produced due to the combination of a non-flammable nonwoven fabric impregnated with a synthetic resin with a decorative material layer made of a decorative paper impregnated with melamine-formaldehyde resin
Data Source
Figure 1
Figure 2a~2d
Figure 3
AI summary
The invention relates to a laminate (1), in particular for manufacturing a construction panel, consisting of a combination of at least one carrier material layer (2) made of a non-flammable non-woven (4) impregnated with a resin (3) and at least one decorative material layer (5) made of a decorative paper (7) that is impregnated with a melamine formaldehyde resin (6) and is optionally dyed and/or printed. The invention further relates to a method for manufacturing a disclosed laminate (1) and especially a construction panel.