Single layer scattering of powder surfaces
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Solution Overview
Problem
The existing production methods for fibre-based panels with decorative surfaces, such as floor panels, face challenges in efficiently mixing and applying materials like wood fibres, melamine formaldehyde binder, aluminium oxide particles, and colour pigments, leading to issues with surface quality, cost, and flexibility in production.
Innovation Solution
The method involves applying separate layers of materials directly on a core, where the chemical reaction and heat from pressing combine and mix the materials, eliminating the need for separate mixing and allowing for precise control of material proportions and application, using specialized scattering equipment to handle each material type effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate mixing of materials is performed before application, then homogeneous distribution of materials is achieved, but production complexity and cost increase
Solution Approach 1:
The patent divides the application process into separate scattering steps for different material layers (fibres, binders, wear resistant particles, pigments) applied sequentially on the core, eliminating the need for pre-mixing all materials together while achieving homogeneous distribution through controlled separate application
Solution Approach 2:
The patent extracts the mixing operation from the production process by applying materials in separate layers directly on the core, removing the complex mixing step while maintaining material distribution through controlled scattering equipment for each layer
2Ease of manufacture
If all materials are mixed together in one batch, then production process is simplified, but control over material proportions and distribution is reduced
Solution Approach 1:
The patent segments the material application into distinct sequential layers (fibres first, then binders, then wear resistant particles, then pigments), allowing simplified production through direct application while maintaining precise control over each material's proportion and distribution through dedicated scattering equipment
Solution Approach 2:
The patent applies different materials with specific local qualities to different layers - fibres provide structural base, binders provide adhesion, wear resistant particles provide surface hardness, and pigments provide colour - with each layer optimized for its specific function while maintaining overall control
3Strength
If thick surface layers are applied for wear resistance, then wear resistance and impact resistance improve, but production time and material consumption increase
Solution Approach 1:
The patent creates a composite surface layer combining fibres, thermosetting binders, wear resistant particles (aluminium oxide), and pigments in a single integrated layer structure, achieving high wear resistance and impact resistance through material composition rather than increased thickness, thus reducing production time
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 approach results in a high-quality, cost-efficient, and flexible production process for fibre-based panels with improved wear resistance, impact resistance, and decorative capabilities, reducing material waste and production costs while enhancing production tolerances.
Implementation Method 1
The binders are thermosetting binders such as melamine formaldehyde... cured under heat and pressure to a 0.1 - 1.0 mm solid surface layer
Implementation Method 2
cured under heat and pressure to a 0.1 - 1.0 mm solid surface layer
Implementation Method 3
The binders are thermosetting binders such as melamine formaldehyde... under heat and pressure
Data Source
Figure 1a~1d
Figure 2a~2c
Figure 3a~3d
AI summary
The disclosure relates to a method of forming a surface layer (5) on a substrate (6). The method comprises forming a first layer of a first material (M1) and applying a second layer of a second material (M2) on the first layer. The first and second layers are mixed into a mix comprising the first and the second material and the mix is applied on the substrate for forming the surface layer.