WPC Laminate Floor Panel Bonding Without Separate Glue
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Solution Overview
Problem
Existing methods for manufacturing laminate floor panels with a wood/plastic composite (WPC) core face challenges in attaching a top laminate without the need for separate glue, while ensuring high quality and reducing warping, and require multiple steps for layer integration.
Innovation Solution
A method involving the use of a melted layer of paper or similar material integrated with the WPC granulate core, which acts as an attachment base for the top laminate, allowing for a single-step pressing process to form a stable core and laminate combination, eliminating the need for separate glue and reducing warping through controlled cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate glue is used to attach the top laminate to the WPC core, then the attachment is reliable, but the manufacturing process becomes more complex and costly
Solution Approach 1:
A paper or fabric layer acts as an intermediary between the WPC core and the top laminate. This intermediate layer is impregnated with resin during the pressing process, creating a strong bond that eliminates the need for separate glue application while ensuring reliable attachment of the laminate to the core.
Solution Approach 2:
The attachment process is merged with the core formation process. The paper layer, resin, and WPC core are combined in a single pressing operation, integrating multiple functions (core formation, attachment base creation, and laminate bonding) into one manufacturing step, thereby reducing process complexity.
2Productivity
If the WPC core is cooled quickly, then the production time is reduced, but internal tension increases causing warping
Solution Approach 1:
The paper or fabric layer provides localized quality control during cooling. This layer distributes the cooling effect uniformly across the WPC core surface, creating different cooling zones that prevent localized stress concentration and reduce internal tension, thereby minimizing warping while maintaining acceptable production time.
Solution Approach 2:
The paper or fabric layer serves as a cushioning element that prevents direct contact between the hot WPC core and the cooling press surface. This intermediate layer缓冲s the thermal shock, allowing for faster cooling without creating excessive internal tension that would cause warping.
3Reliability
If the WPC core is pressed at high temperature, then the layer attachment is effective, but the WPC material may melt again
Solution Approach 1:
The paper or fabric layer acts as a thermal intermediary between the heat source and the WPC core. This layer allows heat transmission necessary for resin curing and effective layer attachment, while simultaneously protecting the WPC core from excessive temperatures that would cause remelting.
Solution Approach 2:
The thin paper or fabric layer functions as a thermal barrier film. It is thin enough to allow necessary heat transfer for bonding, yet sufficient to prevent thermal runaway and remelting of the WPC core during the high-temperature pressing process.
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 enables efficient, low-cost, and environmentally friendly production of high-quality laminate panels with reduced internal tension and warping, while providing a uniform cooling effect and insulating properties that prevent further melting during high-temperature pressing.
Implementation Method 1
heating the granulate to a temperature at which the granulate is substantially in a melted state
Implementation Method 2
a layer of paper or the like, which is melted to the core
Implementation Method 3
pressing the melted layer for forming the core of the panels
Implementation Method 4
may cause a better and more uniform cooling of the WPC material, leading to less internal tension and thus reduced warping
Implementation Method 5
This insulating effect (in the direction of the WPC material) can be used to prevent the WPC material to melt again if further layers are attached to the basic layer under heat
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a method of manufacturing laminate floor panels comprising at least a core (3) containing wood/plastic composite (WPC) and a top layer of laminate (14, 15). It includes the step of providing a granulate of WPC in which natural fibres are encapsulated in polymer plastics. There is provided a layer of granulate which is melted. The melted layer is pressed for forming the core of the panels. The top laminate is attached onto the core to form a sheet (13), and the sheet is finished to form one or more panels. The laminate panel comprises a core (3) made of WPC, a basic layer (10) melted to the core and a top laminate (14, 15) comprising at least one paper layer impregnated with impregnation material, such as melamine resin, and being attached to the basic layer through this impregnation material.