Underlay Material Manufacturing via Heated Roll Protrusions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing underlay materials for parquets and laminates have complex manufacturing processes and face challenges in achieving long-term durability, flexibility, and efficient moisture removal, leading to high production costs.
Innovation Solution
A simplified manufacturing method involving the simultaneous bonding of a cellular plastic material to a sheet material using heated rollers with protrusions to create a uniform underlay material with integrated air provisions, reducing the need for separate bonding operations and enhancing air ducts for moisture expulsion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a separate bonding operation is used to bond cellular plastic material to sheet material, then bonding strength is achieved, but manufacturing process complexity increases
Solution Approach 1:
The patent combines the bonding operation with the air provision formation operation into a single integrated process. The heated roller simultaneously bonds the cellular plastic material to the sheet material and creates air provisions through its protrusion pattern, eliminating the need for separate bonding equipment and operations.
Solution Approach 2:
The heated roller is designed to perform multiple functions: it provides heat for bonding, applies pressure for bonding, and creates air provisions through its protrusion pattern. This multi-functional tool replaces what would traditionally require separate equipment for each function.
2Reliability
If multiple separate operations are used for bonding and air provision establishment, then process control is maintained, but productivity decreases
Solution Approach 1:
The heated roller process allows continuous formation of air provisions and continuous bonding in a single pass through the material. This eliminates the interruption and repositioning that would occur with separate operations, maintaining continuous productive action throughout the process.
3Strength
If conventional bonding methods are used, then material adhesion is achieved, but manufacturing cost increases
Solution Approach 1:
By merging the bonding function with the air provision formation function into a single heated roller operation, the patent eliminates the need for additional bonding equipment, operators, and process steps, thereby reducing overall manufacturing costs while maintaining adhesion quality.
4Ease of operation
If air provisions are established separately after bonding, then air duct functionality is achieved, but process complexity increases
Solution Approach 1:
The air provisions are formed simultaneously with the bonding process rather than as a subsequent separate operation. The heated roller's protrusion pattern creates the air duct structure during the same pass that bonds the materials, integrating what would otherwise be sequential operations.
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 expedites the manufacturing process, improves durability and flexibility, and reduces costs by integrating air provisions and bonding in a single step, resulting in a more efficient and cost-effective underlay material production.
Implementation Method 1
the roll placed against the cellular plastic material layer has its surface provided with protrusions, said protrusions of the roll, or the entire roll, having been heated. Thus, the heated roll protrusions, along with pressing between the rolls, melt the cellular plastic material layer at the protrusions to form grooves in the cellular plastic material and press the melted cellular plastic material to the attachment with the sheet material, thus bonding the molten cellular plastic material thereto.
Data Source
AI summary
A method for manufacturing an underlay material (8) to be set under parquet or a laminate, the underlay material including a sheet material layer (1) and a flexible cellular plastic material layer (3) bonded under the sheet material layer, and a bottom surface of the cellular plastic layer being processed for providing an air space, whereby the bottom surface of the cellular plastic material layer (3) is processed by melting the cellular plastic material locally for providing an air space (9) and for simultaneously bonding the cellular plastic material layer to the sheet material layer (1). An underlay material manufactured by such a method is also described.