Siloxane-Modified Resin for Low-Energy Decorative Panel Pressing
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Solution Overview
Problem
Existing methods for producing decorative panels are energy-intensive and could benefit from improved efficiency and reduced energy consumption, particularly in the application and pressing stages, while maintaining the quality and durability of the final product.
Innovation Solution
A method involving a plate-shaped carrier with a resin layer, a paper or fleece layer, and a resin composition or impregnated overlay, where the resin composition includes siloxane, which is applied and calendered at controlled temperatures, followed by pressing to form a decorative laminate with enhanced release properties and mechanical durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional pressing methods are used to produce decorative panels, then the laminate layers are properly joined and structured, but high energy consumption is required due to high pressing temperatures and long pressing times
Solution Approach 1:
The patent changes the chemical composition parameters of the resin by incorporating siloxane groups (specifically polysiloxane content of 0.1-5% by weight), which fundamentally alters the curing behavior and release properties of the resin system, enabling lower temperature and shorter time pressing cycles while maintaining bond quality
Solution Approach 2:
The siloxane component acts as an intermediary substance that facilitates easier release from the press roll surface during the pressing process, reducing the adhesion between the laminate and press roll, thereby enabling energy-efficient pressing with reduced temperature and time requirements
2Ease of operation
If conventional resin compositions are used, then proper bonding is achieved, but release behavior from the press roll is poor requiring higher energy input
Solution Approach 1:
The resin composition is modified by incorporating siloxane groups (0.1-5% by weight of polysiloxane), which change the surface energy and release properties of the cured resin, enabling easy release from press rolls at lower temperatures and reducing the energy required for the pressing operation
Solution Approach 2:
The siloxane component serves as a release-promoting intermediary that reduces adhesion between the laminate and press roll surface during curing, facilitating easy demolding and release without requiring high energy input or additional release agents
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 energy usage by allowing for lower pressing temperatures and shorter pressing times, improving the release behavior of the pressing agent and mechanical properties of the laminate, leading to increased economic efficiency and durability without compromising the visual or tactile qualities of the panel.
Implementation Method 1
the resin composition applied in process step e) or an impregnating agent of the resin-impregnated overlay applied in process step f) has a siloxane, in particular a polysiloxane
Implementation Method 2
calendering the resulting layer structure, in particular at a temperature between ≧40° and ≦250° C.
Implementation Method 3
calendering the resulting layer structure, in particular at a temperature between ≧40° and ≦250° C.
Implementation Method 4
pressing of the resulting layer structure
Implementation Method 5
pressing of the resulting layer structure
Data Source
Figure 1~2
AI summary
The present invention relates to a method for producing a decorative panel, comprising the process steps of: a) providing a plate-shaped support (110); b) applying a resin layer (120) to the plate-shaped support (110); c) applying a printed or unprinted paper or nonwoven layer (130) to the plate-shaped support (110); d) calendering the resulting layer structure, in particular at a temperature between ≥ 40° and ≤ 250°C; and e) applying at least one resin composition (140). or f) application of a resin-impregnated overlay (150), characterized in that - the resin composition (140) applied in process step e) or an impregnating agent of the resin-impregnated overlay (150) applied in process step f) comprises a siloxane, in particular a polysiloxane, and/or - that the resin composition applied in process step e) or an impregnating agent of the resin-impregnated overlay (150) applied in process step f).A previously described method allows for reduced energy consumption.