Building Panel Binder Impregnation via Solvent Dissolution
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Solution Overview
Problem
Existing methods for producing building panels, such as laminate flooring, face challenges in achieving adequate staining resistance and transparency due to incomplete impregnation of binders into wood particles, leading to opacity and poor adhesion, which results in surfaces that are difficult to clean and prone to staining.
Innovation Solution
A method involving the formation of a mix comprising wood particles, a solvent, and a binder, where the binder is dissolved in the solvent to ensure homogeneous distribution and impregnation of wood particles, improving adhesion and distribution of additives, thereby enhancing staining resistance and transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If binder is applied in dry form to wood particles, then manufacturing process is simpler, but binder distribution is non-uniform and impregnation is incomplete
Solution Approach 1:
The patent changes the physical state of the binder from dry powder to liquid solution form. The binder is dissolved or dispersed in a solvent to create a liquid composition that can be uniformly applied to wood particles through spraying, brushing, or dipping methods, ensuring complete impregnation and homogeneous distribution throughout the particle structure.
Solution Approach 2:
The patent introduces a solvent as an intermediary medium between the binder and wood particles. The solvent facilitates uniform distribution of the binder by carrying it in solution or suspension, allowing complete penetration into wood particle cavities and ensuring consistent adhesion across all particles before the solvent evaporates.
2Productivity
If binder does not fully impregnate wood particles, then application process is faster, but staining resistance and transparency are poor
Solution Approach 1:
The patent changes the binder from dry form to liquid solution form, enabling complete impregnation of wood particles. The liquid state allows the binder to penetrate deep into particle cavities and pores, filling them completely. This thorough impregnation creates a dense, uniform structure that resists staining and improves transparency while maintaining efficient production.
3Quantity of substance
If binder is applied in dry form, then material cost is lower, but adhesion and impregnation are insufficient
Solution Approach 1:
The patent transforms the binder into a liquid solution or dispersion, which significantly improves its ability to penetrate and impregnate wood particles. The liquid form allows complete wetting of particle surfaces and cavities, creating strong adhesive bonds. After application, the solvent evaporates, leaving a uniform, strongly adhered binder layer that provides excellent bonding strength.
4Ease of manufacture
If micro pores are present in the surface, then manufacturing is easier, but cleaning is difficult and staining occurs
Solution Approach 1:
The patent uses liquid binder solution to completely fill and seal micro pores and cavities in the wood particle surface. The liquid binder flows into all pores and solidifies to create a smooth, continuous surface layer. This eliminates micro pores that would otherwise trap dirt and stains, resulting in a surface that is easy to clean and maintain while remaining manufacturable.
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 results in a building panel with improved staining resistance, transparency, and ease of cleaning, as the binder penetrates cavities in wood particles, reducing opacity and micro pores, and allows for efficient distribution of additives, resulting in a more durable and visually appealing surface.
Implementation Method 1
the binder is dissolved in the solvent to ensure homogeneous distribution
Implementation Method 2
the binder penetrates cavities in wood particles, reducing opacity and micro pores
Implementation Method 3
drying the mix
Data Source
AI summary
A method for producing a building panel. The method includes forming a mix including wood particles, a solvent, a binder and optionally at least one additive, wherein the binder and optionally said at least one additive are homogenously distributed in the mix by means of the solvent and wherein the binder impregnates the wood particles, drying the mix, applying the mix on a substrate, and forming a layer by applying heat and pressure to the mix.