Method and device for the production of functionalised wood-based substrates
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Solution Overview
Problem
Conventional flat floor, wall, and ceiling coverings primarily serve decorative purposes and lack integration of additional product features and functions, such as safety aspects and energy efficiency, due to their flat structure and limited functionality.
Innovation Solution
The use of 3D printing technology to apply functional layers with spatial structures and higher layer thicknesses, enabling the integration of features like underfloor heating, lighting, intrusion sensors, and fire alarms, which can be networked with information systems and controlled via devices like smartphones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional printing technology is used to apply decorative layers, then decorative functionality is achieved, but additional product features and functions cannot be integrated
Solution Approach 1:
The patent applies multi-functionality by enabling the printing system to apply both decorative layers and functional layers (such as heating elements, sensors, or conductive patterns) onto the same wood-based substrate in an integrated process, allowing a single product to serve multiple purposes including decoration and active functionality
Solution Approach 2:
The invention merges the previously separate processes of applying decorative coverings and integrating functional elements into a single unified printing process, combining multiple functions (装饰、加热、传感、导电等) into one integrated production step
2Productivity
If multiple separate processes are used to apply decorative layers and functional layers, then each function can be optimized, but production time and complexity increase
Solution Approach 1:
The patent combines multiple separate production processes (decorative layer application, functional layer application, lamination) into a single integrated printing process that applies all layers simultaneously or in sequence without requiring separate production lines or post-processing steps
Solution Approach 2:
The functional layers and decorative layers are applied in a predetermined sequence and configuration during the initial printing process, with functional elements being positioned and prepared on the substrate before final lamination, eliminating the need for subsequent separate processing steps
3Ease of manufacture
If functional layers are applied with flat structure, then manufacturing is simple, but spatial functionality and layer thickness are limited
Solution Approach 1:
The patent changes the physical parameters of the functional layers by applying materials with varying thicknesses, viscosities, and spatial configurations through the printing process, enabling three-dimensional functional structures and varied layer depths while maintaining manufacturing simplicity through digital control
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 approach transforms decorative surfaces into multifunctional elements that enhance safety, energy efficiency, and user convenience, allowing for cost savings and reduced material usage by integrating multiple functions into a single element.
Implementation Method 1
The use of 3D printing technology to apply functional layers with spatial structures and higher layer thicknesses
Implementation Method 2
applying at least one decorative layer to the at least one first functional layer using an analog printer, digital printer and/or 3D printer
Data Source
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AI summary
The present invention relates to a method for printing on wood-based panels (5), in particular wood fiber-based panels, comprising applying a primer to the wood-based panels, applying at least one functional layer (4) to the wood-based panels using a digital printer and/or 3D printer, applying at least one decorative layer (3) to the at least one functional layer using a digital printer and/or 3D printer, and applying at least one protective layer (1) with subsequent drying and/or gelling.The invention further relates to functionalized wood-based panels comprising a carrier panel (5), a counter-layer (6), at least one functional layer (4), at least one decorative layer (3), and at least one protective layer (1), wherein the functional layer can, for example, be configured as a latent heat storage system, underfloor heating, electroluminescent lighting, burglar alarm, or fire alarm. The invention further relates to planar floor coverings, wall and ceiling coverings comprising the functionalized wood-based panels.