Laminate and method for producing same
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Solution Overview
Problem
Conventional laminate production methods, such as multi-daylight and double-belt presses, struggle to efficiently produce large-format laminates with synchronized structures and uniform pressure, leading to asymmetry, moisture penetration, and increased adhesive usage due to surface grinding, which complicates handling and bonding.
Innovation Solution
A laminate with a thickness of less than 2 mm and width of over 1,800 mm, produced using a multi-piston short-cycle press with embossed structures mimicking grinding patterns, allowing for direct coating on support plates and synchronized surface embossing, reducing the need for mechanical grinding and minimizing adhesive usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional multi-daylight presses or double-belt presses are used to produce large-format laminates, then the production capacity and laminate size can be increased, but the pressure uniformity deteriorates leading to asymmetry and bonding defects
Solution Approach 1:
The pressing operation is divided into multiple independent pressing zones along the laminate length. Each zone has its own pressing means that can be independently controlled, allowing uniform pressure distribution across large-format laminates while maintaining manufacturing precision.
2Strength
If mechanical grinding is applied to the laminate surface to improve bonding properties, then the bonding strength to support plates is enhanced, but the resin layer coherence is compromised leading to moisture penetration and increased adhesive usage
Solution Approach 1:
The embossed structure is created during the laminate production process itself, before the bonding stage. This preliminary structuring of the core layer surface provides bonding enhancement without compromising the resin layer integrity, preventing moisture penetration and reducing adhesive requirements.
3Manufacturing precision
If synchronized structure embossing is implemented on the laminate, then the aesthetic appearance and surface quality are improved, but the production complexity and tooling requirements increase significantly
Solution Approach 1:
The embossing of synchronized structures is integrated into the standard pressing process. The pressing means simultaneously apply pressure for laminate formation and emboss the desired surface structures, combining multiple functions into a single operation without requiring separate tooling or production steps.
4Ease of manufacture
If the core layer surface is left smooth for cost-effective production, then the manufacturing cost is reduced, but the bonding properties to support plates deteriorate
Solution Approach 1:
The embossed structure is created during the laminate production process itself, before the bonding stage. This preliminary structuring of the core layer surface provides bonding enhancement without compromising the resin layer integrity, preventing moisture penetration and reducing adhesive requirements.
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 solution enables the production of large-format laminates with improved bonding, reduced moisture penetration, and lower adhesive requirements, while maintaining surface quality and structural integrity, thus simplifying handling and processing.
Implementation Method 1
Owing to the crosslinking of the resins, preferably enhanced by the cellulose fibres of the papers, a very dense material with a closed surface is formed
Implementation Method 2
The application of heat and pressure thereby causes the resins to flow and subsequently harden
Implementation Method 3
pressed together under high pressure and heat
Implementation Method 4
the core layer opposite the decorative layer is embossed to mimic grinding
Data Source
AI summary
A laminate for application onto a support material having a resin-impregnated decorative layer and at least one resin-impregnated core layer. The decorative layer and the at least one core layer are adapted for being pressed together under high pressure and heat. A technical problem of improving a laminate for application onto the support material is solved in that the decorative layer and the at least one core layer can be compressed by a short-cycle press and have a width of more than 1800 mm. A method for producing the laminate is also provided.