Plate-Shaped Product Lamination for Stiffness Without Shrinkage
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Solution Overview
Problem
Existing methods for manufacturing plate-shaped products, such as floor products, face high capital costs and produce products with poor dimensional stability and shrinkage issues due to the need for multiple calender lines and laminating processes, resulting in harder but less flexible products.
Innovation Solution
A method combining multiple coating and calendering processes to create intermediate products, where a carrier, printing, and protective layers are formed using coating, and a calendered plastic layer is laminated onto the carrier, offering improved dimensional stability and stiffness, with optional embossing and thermic cross-linking for enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple calender lines and laminating processes are used to manufacture plate-shaped products, then the products achieve sufficient stiffness for modular shapes, but the capital cost increases significantly and dimensional stability deteriorates with shrinkage phenomena
Solution Approach 1:
The manufacturing process is segmented into two independent stages: (1) a multiple coating process to create a first intermediate product with carrier, printing layer, and protective layer; and (2) a calendering process to create a second intermediate product with plastic layer. These segmented processes eliminate the need for multiple calender lines while maintaining product stiffness through the lamination of the two intermediate products.
Solution Approach 2:
The carrier, printing layer, and protective layer are preliminarily formed through the multiple coating process before the calendering process. This preliminary action allows the plastic layer to be added later through lamination, avoiding the need for complex multi-line calendering setups and reducing capital costs while maintaining dimensional stability.
2Strength
If multiple calender lines and laminating processes are used, then the products achieve sufficient stiffness, but the dimensional stability worsens with shrinkage and poor rest stability
Solution Approach 1:
By segmenting the manufacturing into coating and calendering processes, the patent avoids the continuous high-pressure lamination that causes shrinkage. The first intermediate product from coating maintains dimensional stability, while the second intermediate product from calendering provides stiffness, and their subsequent lamination combines these benefits without significant shrinkage.
3Ease of operation
If a continuous multiple coating process is used to apply layers, then flexible and soft floor products are produced, but the products lack sufficient stiffness for modular shapes
Solution Approach 1:
The patent merges two different manufacturing approaches by combining the first intermediate product from multiple coating (which provides flexibility) with the second intermediate product from calendering (which provides stiffness). The lamination of these two intermediate products creates a composite structure that achieves both flexibility and sufficient stiffness for modular shapes.
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 produces plate-shaped products with excellent dimensional stability and sufficient stiffness for modular shapes, reducing capital costs and minimizing shrinkage while maintaining flexibility, and can include additional surface structures and coatings for enhanced durability and longevity.
Implementation Method 1
manufacturing a first intermediate product which comprises at least, successively, a carrier, a plastic printing layer, a decorative print layer and a plastic protective layer, by using a multiple coating process
Implementation Method 2
manufacturing a second intermediate product which comprises at least one plastic layer, by using at least a calendering process
Implementation Method 3
combining the first and second intermediate products by laminating, such that the second intermediate product is attached to the first intermediate product
Data Source
AI summary
A method is presented for manufacturing a plate shaped product, comprising the steps of manufacturing a first intermediate product which comprises at least, successively, a carrier, a plastic printing layer, a decorative print layer and a plastic protective layer, by using a multiple coating process, manufacturing a second intermediate product which comprises at least one plastic layer, by using at least a calendering process, and combining the first and second intermediate products by laminating, such that the second intermediate product is attached to the first intermediate product. Further a plate shaped product is provided which is manufactured using said method.