Warpage control method during surface forming process of plastic film-reinforced flexible decorative veneer

The plastic film of the new plastic film reinforced pliable decorative veneer (PRPDSV) is used as a flexible reinforcement material and an adhesive material. It has good water resistance, impermeability, simple preparation and finishing processes, and no formaldehyde release. However, warpage phenomenon during hot pressing has been a bottleneck problem restricting its industrial development. In order to solve this problem solve, the study proposed a concave, and convex molds method, established an elastic-plastic FEA model of hot pressing processes of the PRPDSV using concave and convex molds with static/general static solution module in the nonlinear ABAQUS, and researched the effect on the performances of the PRPDSV from the parameters of temperature, pressure, and mold curvature radius theoretically and verified experimentally. Analysis results showed that the surface forming temperature had a great effect on warpage control for PRPDSV. The higher the temperature is, the smaller the curvature radius of the corresponding mold will be and the better the warpage will be. The curvature radius of the molds had a significant effect on the warpage control. Under the conditions with the same hot pressing parameters, the smaller the curvature radius is, and the better control on the warpage for the PRPDSV will be.

Automated summary

A new method using concave and convex molds for hot pressing was proposed to effectively control warpage issues of PRPDSV and improve quality stability. Surface forming temperature and mold curvature radius are key factors that affect warpage of PRPDSV.