Uncured Wood Fibre Floor Layer Handling via Carrier Support
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Solution Overview
Problem
The handling of 'paper free' Wood Fibre Floor (WFF) layers is challenging due to their brittleness, making them difficult to handle and store without damage, and they require additional binders when attached to a core.
Innovation Solution
A method of manufacturing a continuous, uncured layer by applying a powder mix of fibres and a thermosetting binder on a carrier, forming a connected layer that can be released and attached to a core with heat and pressure, eliminating the need for additional binders and reducing brittleness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a powder mix layer is cured to form a solid surface layer, then wear resistance and structural integrity are improved, but the layer becomes brittle and difficult to handle
Solution Approach 1:
The patent applies preliminary action by forming and curing the powder mix layer on a carrier sheet before detachment. This allows the layer to gain structural integrity and wear resistance while still supported by the carrier, preventing brittleness-related handling issues. The carrier provides temporary support during handling and storage, and the cured layer is only detached when ready for final installation on the core.
2Ease of operation
If a cured layer is detached from the carrier, then the layer can be handled separately, but it becomes brittle and prone to damage
Solution Approach 1:
The layer is cured on the carrier in advance, achieving full structural integrity before detachment. This preliminary curing ensures the layer is as strong as possible before it needs to be handled separately, minimizing brittleness-related damage risks.
Solution Approach 2:
The carrier sheet acts as an intermediary that provides mechanical support during the handling and storage of the cured layer. The carrier protects the brittle cured layer from damage, and this protective role continues until the layer is ready for final installation, at which point the carrier is removed.
3Strength
If additional binders are used to attach the layer to the core, then bonding strength is improved, but the process complexity increases
Solution Approach 1:
The patent merges the bonding function into the powder mix layer itself by incorporating a binder component in the powder mix. This eliminates the need for separate additional binders, as the layer's own binder provides sufficient bonding strength when the layer is attached to the core under heat and pressure.
Solution Approach 2:
The powder mix layer serves multiple functions: it provides the wear-resistant surface, acts as the bonding agent to the core, and forms the structural layer. The binder in the powder mix is multi-functional, providing both structural integrity within the layer and bonding capability to the core, eliminating the need for separate binder applications.
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 allows for a flexible, semi-finished product that can be handled and stored without damage, and can be easily attached to a core with simultaneous curing, enhancing handling and storage capabilities while eliminating the need for additional binders.
Implementation Method 1
forming a connected layer that can be released and attached to a core with heat and pressure
Implementation Method 2
a powder mix of fibres and a thermosetting binder
Implementation Method 3
attached to a core with heat and pressure, eliminating the need for additional binders and reducing brittleness
Implementation Method 4
attached to a core with heat and pressure
Data Source
AI summary
A method of manufacturing a separate and continuous layer being essentially uncured. The method includes applying a powder mix including fibres and a thermosetting binder on a carrier, forming a powder mix layer, wherein the powder mix is connected together such that the powder mix layer is obtained and wherein the powder mix layer is essentially uncured, and releasing the powder mix layer from the carrier. Also, a layer and a method for manufacturing a building panel.