Wood-Powder Building Element Coating for Uniform Layering
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Solution Overview
Problem
Existing methods for producing wooden floor coverings face challenges such as uneven distribution of wood powder due to bridging and ratholing, leading to non-uniform thickness and increased tension during curing, which affects the quality and cost efficiency of the process.
Innovation Solution
Incorporating fine non-pigment cohesive particles with a specific concentration between 0.05 wt% and 9 wt% in the mixture of binder and filler, which coat the wood powder, improving flowability and reducing mechanical interlocking, resulting in a uniform thickness and reduced need for balancing layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wood powder is scattered in dry powder form on a wood based core, then the layer can be applied to the substrate, but the wood powder exhibits poor flowability and creates uneven distribution due to bridging and ratholing
Solution Approach 1:
A flow agent is introduced as an intermediary substance between the wood powder particles and the substrate. This flow agent modifies the interaction between wood powder particles, reducing mechanical interlocking and enabling smoother flow during scattering, thereby achieving uniform distribution without bridging or ratholing
Solution Approach 2:
The physical or chemical parameters of the wood powder mixture are changed by adding the flow agent, which alters particle surface properties and inter-particle friction. This parameter change enables the wood powder to flow more freely and distribute uniformly across the substrate during the scattering process
2Manufacturing precision
If the mix is cured under heat and pressure to form a surface layer, then the layer is formed on the core, but shrinking of the binder leads to tension and warping of the panel
Solution Approach 1:
A balancing layer is applied to the rear side of the core before the first layer is cured. This balancing layer performs preliminary counter-action by providing opposite tension to compensate for the shrinkage tension that will develop in the first layer during curing, preventing warping before it occurs
Solution Approach 2:
The curing parameters (heat and pressure) are controlled to manage the shrinkage process. By optimizing these parameters, the shrinkage is minimized and controlled, reducing the development of tension that causes warping while still achieving proper curing of the binder
3Stability of the object's composition
If a balancing layer is added to compensate for tension, then warping is prevented, but the device complexity and manufacturing cost increase
Solution Approach 1:
The composition and properties of the first layer are modified by adjusting the binder type, filler content, and curing parameters. These parameter changes enable the first layer itself to have reduced shrinkage and tension, potentially eliminating or reducing the need for a separate balancing layer
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 ensures a uniformly thick first layer with improved distribution and reduced material stress, enhancing the quality and cost efficiency of the manufacturing process while maintaining aesthetic and functional properties.
Implementation Method 1
The cohesive particles may be fine cohesive particles. Fine particles may be defined as at least 70% of the particles having a length in their largest dimension of 2.5 μm or less
Implementation Method 2
improving flowability and reducing mechanical interlocking
Implementation Method 3
applying heat and/or pressure to the first layer and/or substrate, thereby forming the building element
Implementation Method 4
applying heat and/or pressure to the first layer and/or substrate, thereby forming the building element
Implementation Method 5
After the mix has been applied on the core, the mix is thereafter cured under heat and pressure to a 0.1-1.0 mm thick surface layer arranged on the core
Implementation Method 6
the binder, which is the other main component of the mix, usually comprises more free flowing particles
Data Source
AI summary
A method of manufacturing a building element, including applying a first layer on a first surface of a substrate, the first layer including a mixture of a binder, at least one filler and fine non-pigment cohesive particles, wherein an amount of the fine non-pigment cohesive particles in the mixture may be between 0.05 wt % and 9 wt % of the mixture, and applying heat and/or pressure to the first layer and/or the substrate thereby forming the building element. The disclosure further relates to such a building element.