Homogeneous Polyester Composite Board Extrusion
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Solution Overview
Problem
Existing composite board manufacturing methods are not environmentally friendly, energy-efficient, or carbon-neutral due to the use of heterogeneous lamination and extrusion processes that require glues and heat pressing, leading to solvent volatilization and high energy consumption.
Innovation Solution
A polyester composite board structure is manufactured using a multi-layer extrusion method without gluing or heat pressing, where polyester layers and films are extruded and laminated using a wheel at controlled temperatures to form a single-material board with decorative, anti-bacterial, and wear-resistant properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heterogeneous lamination or extrusion methods are used to manufacture composite boards, then the board structure can be formed with multiple materials, but the process requires coating or impregnating glue, causing solvent volatilization and high energy consumption
Solution Approach 1:
The patent uses homogeneous polyester material for all layers (1 to 5 layers) instead of heterogeneous materials like PVC and ABS. This allows the board to be manufactured through single-material extrusion without requiring glues or heat pressing, eliminating solvent volatilization and reducing energy consumption while maintaining the composite board structure
Solution Approach 2:
The patent extracts and removes the harmful elements (glue, heat pressing, solvent) from the manufacturing process. By using homogeneous polyester material that can be extruded in multiple layers without adhesive, the patent eliminates the need for coating or impregnating glue, thereby reducing energy consumption and environmental harm
2Ease of manufacture
If heterogeneous lamination with glue coating is used, then composite board structure can be achieved, but solvent volatilization and carbon emissions occur
Solution Approach 1:
The patent employs homogeneous polyester material throughout all layers, eliminating the need for heterogeneous material bonding agents. This single-material approach prevents solvent volatilization and carbon emissions associated with glue coating, while still achieving the desired composite board structure through layered extrusion
Solution Approach 2:
The patent converts the potential harm of requiring multiple materials into a benefit by using homogeneous polyester that can be extruded in multiple layers without adhesive. This transforms the manufacturing process from harmful (glue-based) to beneficial (adhesive-free), eliminating solvent volatilization and carbon emissions
3Reliability
If multiple layers of different materials are extruded, then the composite board can have enhanced functional properties, but the manufacturing process becomes more complex
Solution Approach 1:
The patent uses homogeneous polyester material for all layers, which simplifies the manufacturing process compared to heterogeneous materials. The single-material property allows for easier control during extrusion and eliminates the need for complex bonding processes, while still achieving enhanced functional properties through layer differentiation in thickness and position
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 reduces environmental impact, conserves energy, and minimizes carbon emissions while producing a composite board with enhanced properties, aligning with current demands for sustainability and green products.
Implementation Method 1
the melting temperature of the multi-layer extrusion equipment is 250° C. to 290° C.
Implementation Method 2
laminating a polyester film by heat using a wheel during an extrusion process
Implementation Method 3
laminating a polyester film by heat using a wheel during an extrusion process
Data Source
AI summary
The disclosure provides a polyester composite board structure and a manufacturing method thereof. The manufacturing method includes extruding a polyester layer into a board using a multi-layer extrusion equipment, and laminating a polyester film by heat using a wheel during an extrusion process.