3D Textured Decorative Board With Protected Wear-Resistant Layer
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Solution Overview
Problem
Existing methods for forming 3D textures on decorative boards fail to achieve a realistic visual and tactile effect, particularly in mimicking real wood grain, and often compromise wear resistance and pattern clarity due to the damage of the pattern layer during texture formation.
Innovation Solution
A board with a 3D texture structure comprising a substrate, a pattern layer, a wear-resistant layer with a thickness adjustment layer and a texture layer, where the thickness adjustment layer is pre-cured to protect the pattern layer and ensure wear resistance, and the texture layer has grooves formed without penetrating the thickness direction, enhancing bonding strength and clarity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the wear-resistant layer is brushed while in a semi-cured or uncured state to form the texture layer, then the 3D texture structure can be formed, but the structure of the wear-resistant layer is damaged, reducing wear resistance and even damaging the pattern layer
Solution Approach 1:
The wear-resistant layer is divided into two separate layers: a pre-cured wear-resistant layer that protects the pattern layer, and a texture layer formed by brushing embossing liquid that creates the 3D texture. This segmentation allows the wear-resistant function and texturing function to be independent, resolving the contradiction between forming 3D texture and maintaining wear resistance.
Solution Approach 2:
The wear-resistant layer is pre-cured before the texture layer is formed. This preliminary curing action creates a protective barrier that prevents damage to the pattern layer during the subsequent brushing process, while still allowing the texture layer to be formed with proper adhesion.
2Shape
If the wear-resistant layer is brushed to form the texture layer, then the 3D texture structure can be formed, but the pattern layer is damaged, reducing pattern clarity
Solution Approach 1:
The wear-resistant layer is segmented into a pre-cured wear-resistant layer and a texture layer. The pre-cured layer acts as a protective barrier that preserves pattern clarity, while the texture layer provides the 3D texture without compromising the underlying pattern layer.
Solution Approach 2:
The pre-cured wear-resistant layer serves as an intermediary between the pattern layer and the texture layer. It mediates the interaction by providing a stable, cured surface that protects the pattern layer from damage during texture formation, while still allowing proper adhesion of the texture layer.
3Device complexity
If a single wear-resistant layer is used to form both the protective layer and the texture layer, then the process is simplified, but the bonding strength is insufficient and the pattern clarity is compromised
Solution Approach 1:
The single wear-resistant layer is segmented into two functional layers: a pre-cured wear-resistant layer for protection and adhesion, and a texture layer for creating the 3D texture. This segmentation increases bonding strength while maintaining reasonable structural complexity.
Solution Approach 2:
Different regions of the coating system are assigned different properties: the pre-cured wear-resistant layer has high crosslinking density for strength and protection, while the texture layer has optimized composition for texture formation. This local differentiation of properties resolves the contradiction between simplicity and bonding strength.
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 provides superior wear resistance, clarity, and a tactile feel closer to natural wood grain, with improved bonding strength and deeper 3D textures without compromising pattern clarity.
Implementation Method 1
applying embossing liquid to at least a portion of the surface of the texture layer; curing the texture layer and removing the uncured or incompletely cured parts
Implementation Method 2
curing the texture layer and removing the uncured or incompletely cured parts
Data Source
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AI summary
The present invention relates to the technical field of decorative panels, in particular to a panel with a 3D textured structure, its preparation method, and applications. The panel, from bottom to top, at least includes a substrate, a pattern layer, an abrasion-resistant layer, and a topcoat layer. The abrasion-resistant layer comprises a thickness-adjusting layer and a texture layer located above the thickness-adjusting layer. The texture layer includes a base portion and a three-dimensional portion, the three-dimensional portion being positioned above the base portion. The pattern layer contains multiple wood grain-shaped lines, which may be connected or disconnected. The three-dimensional portion comprises multiple wood grain-shaped grooves, which may be connected or disconnected, wherein at least some of the grooves correspond to the lines in one or more of arrangement position, length, or width. The top of at least part of the topcoat layer is lower than the upper surface of the three-dimensional portion. The panel of the present invention provides excellent wear resistance, while achieving better 3D texture clarity, improved tactile feel, and enhanced visual effect.