Patterned Composite Product Permeation Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional methods for creating patterned composite products, such as laminates for building and furniture, often result in applied images being damaged or costly, and require multiple steps for surface coating and treatment to mimic natural materials.
Innovation Solution
A method involving a substrate with a porous structure, a sheet-form curable material, and a patterned sheet where the curable material permeates into both the substrate and the patterned sheet under pressure, forming a strong bond and ensuring the pattern's visibility and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If applied images or surface coatings are used to create patterns on composite products, then the aesthetic appearance is improved, but the images are subject to damage during use and the application process becomes costly and time consuming
Solution Approach 1:
The patterned sheet is integrated directly into the composite product structure during the moulding process, merging the pattern layer with the substrate and skin layers. This eliminates separate application steps and ensures the pattern becomes an inherent part of the product, resistant to damage during use.
Solution Approach 2:
The pattern is pre-applied to a sheet before the moulding process, allowing the patterned sheet to be inserted as a complete unit into the mould. This preliminary patterning avoids post-manufacturing application steps and ensures the pattern is protected throughout the composite formation process.
2Ease of manufacture
If multiple surface coatings and treatments are applied to mimic natural materials, then the resemblance to traditional materials is improved, but the manufacturing process complexity increases
Solution Approach 1:
Multiple functional layers including the patterned sheet, substrate, and skin are combined into a single integrated composite product formed in one moulding operation. This merging eliminates multiple separate manufacturing steps required for traditional surface coating and treatment processes.
Solution Approach 2:
The invention uses a composite structure comprising a substrate, patterned sheet, and skin layer that work together to achieve both aesthetic resemblance to natural materials and structural integrity. This composite approach consolidates multiple functions into a single manufactured component.
3Strength
If the curable material is pressed into the substrate and patterned sheet, then the bonding strength is improved, but the material movement in the plane of the mould increases which can damage the patterned sheet
Solution Approach 1:
The curable material is applied as a continuous sheet extending across the whole surface, creating uniform local bonding characteristics throughout. This prevents localized material movement that could damage the patterned sheet while maintaining adequate bonding strength through the entire surface area.
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 method enhances the bonding between the substrate and the patterned sheet, reducing the risk of pattern damage and simplifying the manufacturing process while achieving a durable, visually appealing composite product with improved surface finish.
Implementation Method 1
a component of the sheet-form curable material passing into a surface of the substrate and also into a surface of the patterned sheet
Implementation Method 2
the patterned sheet is permeable in respect of at least a component of the sheet-form material
Data Source
AI summary
The present invention relates to methods for forming a composite product having a patterned surface. A substrate including a porous structure (136), a sheet-form material (134) and a patterned sheet (131) are pressed together to form the composite product. In preferred examples, the patterned sheet is permeable to curable material in the sheet-form material.