Plastic Fiber Laminate Bonding Without Synthetic Resin
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Solution Overview
Problem
Existing laminate production methods require a separate synthetic resin layer to bond real wood veneer with a carrier board, making the process complex and inefficient.
Innovation Solution
A method involving the production of a pre-compressed fiber mat with wood and plastic fibers, where the plastic fibers melt during pressing to bind the wood fibers and veneer, eliminating the need for a synthetic resin layer, and allowing the plastic to penetrate the veneer for enhanced moisture resistance and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate synthetic resin layer is used to bond real wood veneer with carrier board, then bonding reliability is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent merges the bonding agent function into the carrier board itself by incorporating plastic fibers that melt during pressing to create adhesive bonds. This eliminates the separate synthetic resin layer while maintaining bonding reliability, directly resolving the contradiction between bonding reliability and manufacturing complexity.
Solution Approach 2:
The patent extracts and removes the separate synthetic resin layer from the laminate structure, relying instead on the plastic fibers within the carrier board to provide bonding. This simplifies the manufacturing process while preserving the essential bonding function.
2Strength
If multiple separate layers and binder applications are used, then bonding strength is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The patent combines the bonding agent function into the carrier board's plastic fibers, which melt during the single pressing operation to create strong bonds between veneer layers. This eliminates multiple separate binder application steps while maintaining bonding strength, directly addressing the contradiction between strength and manufacturing time.
Solution Approach 2:
The patent utilizes the phase transition of plastic fibers from solid to molten state during pressing to create bonding. This thermal melting process occurs during the single pressing step, providing strong adhesion without requiring separate binder applications, thus reducing manufacturing time while maintaining bond strength.
3Ease of manufacture
If plastic fibers are used to bond wood fibers without additional synthetic resin, then manufacturing simplicity is improved, but bonding reliability may worsen
Solution Approach 1:
The patent enables the carrier board's plastic fibers to serve their own bonding function, melting during pressing to create adhesive bonds without requiring external synthetic resin layers. This self-bonding mechanism simplifies manufacturing while maintaining reliability, directly resolving the contradiction between ease of manufacture and bonding reliability.
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
Simplifies laminate production by eliminating the need for a synthetic resin layer, while ensuring reliable bonding and increased moisture resistance and dimensional stability of the real wood veneer.
Implementation Method 1
During this process, the fiber mat is reduced from a thickness of, for example, 25 mm to 30 mm to a thickness of, for example, 1.3 mm.For example, it is compressed to 4 mm to 5 mm, resulting in a substrate with a density of, say, 800 kg/m3. During the pressing process, at least the plastic fiber melts from its surface, and the softened or liquefied plastic binds the wood fibers and the plastic fibers to each other.
Implementation Method 2
The softened or liquefied plastic also penetrates at least the outer layer of the veneer that lies against the fiber mat, thus bonding the real wood veneer to the fiber mat or to the substrate made of wood and plastic fibers that is created during the pressing process.
Implementation Method 3
The fiber mat with the real wood veneer applied to it is transferred to a hot press, preferably a continuous hot press, and pressed at a temperature of 140 °C to 190 °C, advantageously at a temperature of 160 °C to 180 °C, and at a pressure of 10 MPa to 45 MPa, to form a laminate
Implementation Method 4
The fiber mat with the real wood veneer applied to it is transferred to a hot press, preferably a continuous hot press, and pressed at a temperature of 140 °C to 190 °C, advantageously at a temperature of 160 °C to 180 °C, and at a pressure of 10 MPa to 45 MPa, to form a laminate
Implementation Method 5
The laminate is then cooled under pressure in the press.
Data Source
Figure 1~2
AI summary
The invention relates to a method for producing a laminate comprising the steps of: producing a pre-compressed fiber mat, comprising wood fibers and plastic fibers, as a substrate; applying a real wood veneer to the top surface of the fiber mat; and pressing the real wood veneer, fiber mat, and backing layer together to form a laminate. The invention further relates to a laminate with a substrate comprising wood fibers and plastic fibers, wherein a real wood veneer is applied to the top surface of the laminate.