Method for manufacturing a plate shaped product and plate shaped product manufactured thereby
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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, plastic printing, and decorative layers are coated, and then laminated with calendered plastic layers, offering improved dimensional stability and stiffness, with optional surface structures and thermic cross-linking for enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple calender lines and laminating processes are used, then manufacturing capability is improved, but capital cost increases and dimensional stability deteriorates
Solution Approach 1:
The manufacturing process is divided into two independent stages: first producing a printed plastic web with decorative and protective layers, then separately producing thermoplastic layers via calendering, and finally laminating them together. This segmentation allows each stage to be optimized independently, reducing the need for multiple complex calender lines while improving dimensional stability through the stable base layer.
Solution Approach 2:
The final product combines two distinct material systems: a printed plastic web (providing dimensional stability and decorative properties) and thermoplastic layers (providing mechanical properties and flexibility). This composite structure leverages the advantages of each material system while mitigating their individual disadvantages, achieving both dimensional stability and manufacturing efficiency.
2Strength
If calendering and laminating processes are used, then product stiffness is improved, but shrinkage and dimensional stability worsen
Solution Approach 1:
The printed plastic web is produced first and allowed to stabilize before the thermoplastic layers are added. This preliminary action ensures that the base layer achieves its final dimensions and stability characteristics before subsequent layers are laminated, preventing shrinkage issues that would occur if layers were combined and then processed.
Solution Approach 2:
The process utilizes temperature and pressure parameter changes during the lamination stage to bond the thermoplastic layers to the printed web without causing shrinkage. By carefully controlling these parameters, the product achieves the desired stiffness while maintaining dimensional stability.
3Productivity
If continuous multiple coating process is used, then manufacturing efficiency is improved, but product hardness and flexibility are compromised
Solution Approach 1:
The printed plastic web acts as an intermediary carrier that provides dimensional stability and decorative properties, while the separately produced thermoplastic layers provide the required mechanical hardness and flexibility. This intermediary approach allows each layer to be optimized for its specific function without compromising the other properties.
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 reduces capital costs and produces plate-shaped products with excellent dimensional stability and stiffness, minimizing shrinkage and enhancing the product's mechanical properties, while maintaining flexibility.
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
Implementation Method 4
optional surface structures and thermic cross-linking for enhanced durability
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.