Laminated Panel Adhesive Zoning for Clean Layer Delamination
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Solution Overview
Problem
Existing decorative panels with laminated structures face challenges in clean separation of layers during recycling due to the use of permanent adhesives, leading to contaminated material streams and compromised recycling efficiency.
Innovation Solution
The panels incorporate an intermediate adhesive layer with alternating adhesive and non-adhesive zones, allowing for durable bonding during use and facilitated delamination post-use, enabling clean separation of layers for recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If permanent adhesives are used to bond layers, then durable adhesion is achieved, but layer separation becomes difficult and contamination occurs during recycling
Solution Approach 1:
The adhesive layer is segmented into multiple zones with different adhesive properties. Adhesive zones provide strong bonding in specific areas, while non-adhesive zones enable layer separation. This segmentation allows the same adhesive layer to fulfill both functions of strong bonding and easy separation, resolving the contradiction between durable adhesion and ease of layer separation.
Solution Approach 2:
Different zones within the adhesive layer have locally different properties. Some zones are designed to be highly adhesive to ensure durable bonding during panel use, while other zones are designed to be non-adhesive to facilitate layer separation during recycling. This local differentiation allows the adhesive layer to provide both strong bonding and easy separation simultaneously.
2Reliability
If permanent adhesives are used to bond layers, then durable bonding is achieved, but clean delamination cannot be accomplished
Solution Approach 1:
The adhesive layer is divided into adhesive zones and non-adhesive zones. The non-adhesive zones act as pre-defined separation paths that guide the delamination process, ensuring that layers separate cleanly along these zones without contaminating each other. This segmentation maintains bonding durability in adhesive zones while enabling clean delamination through non-adhesive zones.
Solution Approach 2:
The non-adhesive zones within the adhesive layer serve as intermediary regions that facilitate clean separation. These zones act as mediators between the adhesive zones, allowing layers to delaminate cleanly without direct contact between adhesive surfaces, thereby preventing contamination while maintaining bonding durability in the adhesive zones.
3Force
If excessive delamination forces are applied to break adhesive bonding, then layer separation is achieved, but clean separation is compromised
Solution Approach 1:
The adhesive layer is segmented into adhesive zones and non-adhesive zones. The non-adhesive zones require minimal force to separate, allowing layer delamination to proceed with low delamination forces. This segmentation eliminates the need to apply excessive forces that would otherwise be required to break strong adhesive bonds, thereby enabling both easy separation and clean delamination.
Solution Approach 2:
Adhesive properties are extracted from specific zones of the adhesive layer, creating non-adhesive zones. These zones are removed of adhesive functionality, allowing layers to separate easily and cleanly without requiring excessive delamination forces. This extraction of adhesive properties in specific zones enables clean separation while maintaining bonding in the remaining adhesive zones.
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 design ensures durable adhesion during panel use while allowing for efficient, clean delamination and improved purity of recycled material streams.
Implementation Method 1
at least two layers of the panel, in particular the top layer and the core layer, are directly or indirectly adhered to each other by an intermediate adhesive layer
Data Source
AI summary
A panel, in particular a floor, ceiling, or wall panel, of a planar design having a top side, a bottom side and multiple side edges, which panel has a laminated structure of layers that are adhered to each other. The layers extend parallel to the plane of the panel, and include a core layer having a lower side and an upper side, and a top layer which is provided on the upper side of the core layer either directly or indirectly. At least two layers of the panel, in particular the top layer and the core layer, are directly or indirectly adhered to each other by an intermediate adhesive layer. The intermediate adhesive layer is composed of adjacent intermediate zones which include non-adhesive intermediate zones and adhesive intermediate zones, which intermediate adhesive layer establishes an adhesive strength between the two layers, such that a durable adhesion between the two layers is obtained, and a clean delamination of the two layers is allowed for when the two layers are subjected to a sufficient delamination force.