Glue-Free Thermoplastic Laminate Sheet for Flat Rigid Panels
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Solution Overview
Problem
Existing thermoplastic laminate sheets for furniture and structures made of wood or particleboard suffer from deformations, edge bending, cracking, non-uniform color, excessive glue usage, and humidity-related issues, lacking mechanical resistance and flatness comparable to High Pressure Laminates (HPL) sheets.
Innovation Solution
A thermoplastic laminate sheet composed of multiple thermoplastic layers, including a superficial and basic layers, is manufactured through a coupling process without glue, using controlled heating and pressing, achieving uniform thickness and rigidity, and enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If HPL sheets are used to achieve mechanical resistance and flatness, then strength and stability are improved, but deformation and edge bending occur due to differential stress between various layers
Solution Approach 1:
The patent applies homogeneity by using multiple layers of thermoplastic material instead of composite materials with different properties. All layers are made of the same thermoplastic material, ensuring uniform thermal and mechanical behavior throughout the laminate structure. This eliminates the differential stress and deformation issues that occur in HPL sheets where paper layers and resin overlays have different properties.
Solution Approach 2:
The patent creates a composite thermoplastic laminate structure by bonding multiple thermoplastic layers together. While using the same base material, the layered composite structure provides enhanced mechanical resistance and flatness compared to single-layer sheets, while maintaining dimensional stability through uniform material composition.
2Ease of manufacture
If thermoplastic films are used to reduce thickness and simplify structure, then ease of manufacture is improved, but mechanical resistance and shock resistance are insufficient
Solution Approach 1:
The patent merges multiple thin thermoplastic layers into a single laminate structure that achieves the mechanical resistance of thick sheets while maintaining the manufacturing simplicity of thin films. The layered structure combines the advantages of both thin films (ease of manufacture, flexibility) and thick sheets (mechanical strength).
3Strength
If multiple layers are glued together to increase thickness and rigidity, then strength is improved, but glue consumption increases and application complexity increases
Solution Approach 1:
The patent applies self-service by enabling the thermoplastic layers to bond to each other through their own thermal properties. During the heating and pressing process, the thermoplastic material itself becomes adhesive, allowing layers to fuse without requiring separate glue materials. This eliminates glue consumption while maintaining layer bonding.
4Reliability
If HPL sheets are applied by pressing to achieve good adhesion, then reliability is improved, but excessive glue is consumed and application difficulty increases
Solution Approach 1:
The patent applies parameter changes by utilizing the temperature-dependent properties of thermoplastic materials. During application, the material is heated to become soft and adhesive, then cooled to solidify and bond firmly. This thermal parameter change enables reliable adhesion while simplifying the application process compared to HPL sheets that require extensive glue application and pressure control.
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 laminate sheet achieves improved mechanical resistance, flatness, color uniformity, and humidity resistance, with impact resistance comparable to HPL sheets, while reducing glue usage and facilitating application, and maintaining structural integrity in humid environments.
Implementation Method 1
a first operation of heating only a contact surface between the first layer (21) and the second layer (22) to the softening point
Implementation Method 2
a second operation of coupling by pressing the first layer (21) and the second layer (22)
Data Source
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Figure 5
AI summary
There is described a sheet (10) of thermoplastic laminate (1) consisting only of a multiplicity of thermoplastic layers (11-18) comprising at least one superficial thermoplastic layer (11) and at least two basic thermoplastic layers (12-18), said multiplicity of thermoplastic layers (11- 18) is made of any material of a list comprising PVC, PET, PETG, PP, PE, the thickness of said sheet (10) of thermoplastic laminate (1) being from 0.75 to 4 mm, said sheet (10) of thermoplastic laminate (1) being plane, flat and rigid.