Non-Circular String Embossing for Layered Material Surface Structure
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Solution Overview
Problem
Existing methods for manufacturing layered materials with surface structures face challenges such as high costs, poor aesthetics, prolonged press times, unsatisfactory friction and wear resistance, and dust generation due to the use of expensive and heavy structured press plates or wire meshes.
Innovation Solution
A method involving the use of strings with non-circular cross-sections for embossing a surface structure onto a resin-substrate combination during hot-pressing, which reduces hot-pressing time, minimizes dust generation, and improves resin bonding, resulting in materials with enhanced friction, wear resistance, and aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If structured press plates are used to imprint surface structure, then surface structure is achieved, but cost increases and handling becomes difficult
Solution Approach 1:
The invention extracts the surface structure function from the press plate itself and transfers it to a separate, removable insert. This allows the main press plate to remain simple and easy to handle while the insert provides the necessary surface structure. The insert can be easily removed and replaced without affecting the press plate.
Solution Approach 2:
The press system is segmented into a simple press plate and a separate insert component. The insert contains the surface structure and can be independently handled, stored, and replaced. This segmentation eliminates the need to handle heavy structured press plates while maintaining the surface structure functionality.
2Shape
If wire mesh is used as intermediate layer, then surface structure is achieved, but press time increases
Solution Approach 1:
The invention uses a disposable or easily replaceable insert that can be quickly exchanged between presses. This eliminates the need for prolonged press times to cool or reposition wire meshes. The insert is designed for rapid application and removal, significantly reducing the overall press time required.
3Shape
If wire mesh is used as intermediate layer, then surface structure is achieved, but friction and wear resistance become unsatisfying
Solution Approach 1:
The invention changes the material parameters of the insert to optimize friction and wear resistance. By selecting appropriate materials and surface treatments for the insert, the system achieves superior friction and wear resistance compared to wire mesh, while maintaining the desired surface structure.
4Shape
If wire mesh is used as intermediate layer, then surface structure is achieved, but aesthetics deteriorate due to dust generation
Solution Approach 1:
The invention extracts the surface structure function from the press plate and places it in a separate insert that can be easily cleaned and maintained. This separation prevents dust generation during the pressing process and allows for easier cleaning of the press equipment, improving overall aesthetics.
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 method significantly reduces hot-pressing time, minimizes dust generation, and enhances the quality of the layered materials by improving friction, wear resistance, and aesthetics, while maintaining energy efficiency and reducing maintenance needs.
Implementation Method 1
heat and pressure are applied (hot-pressing) to said layered formation
Implementation Method 2
heat and pressure are applied (hot-pressing) to said layered formation, wherein the at least one string with a non-circular section 10 can serve as a negative for embossing a surface structure
Data Source
Figure 1(A)~1(D)
Figure 2(A)~2(D)
Figure 3(A)~4(F)
AI summary
The invention relates to a method of manufacturing layered materials with a surface structure, wherein at least one string with a non-circular cross-section is used as a negative for the surface structure.