3D Wood Grain Printed Panel With Complete Embossing Layer Removal
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Solution Overview
Problem
Existing methods for creating a three-dimensional wood grain structure on SPC flooring fail to thoroughly remove the embossing layer, resulting in a texture that is not delicate and natural, with poor visual and tactile realism.
Innovation Solution
A method involving a pretreatment step where a pretreatment agent is applied to the embossing layer to reduce its viscosity and hardness, followed by a post-treatment step to remove residual embossing liquid, ensuring a realistic three-dimensional wood grain structure with sharp edges and accurate alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional embossing methods are used to create three-dimensional wood grain structure on SPC flooring, then the production process can be simplified, but the embossing layer cannot be thoroughly removed resulting in poor texture quality and unrealistic appearance
Solution Approach 1:
The patent applies a pretreatment agent to the embossing layer before removal to reduce its viscosity and hardness. This preliminary action modifies the physical properties of the embossing layer, making it easier to remove completely and achieve delicate, natural wood grain texture without compromising production efficiency.
Solution Approach 2:
The patent changes the physical parameters (viscosity and hardness) of the embossing layer by applying a pretreatment agent. This parameter modification enables thorough removal of the embossing layer while maintaining production simplicity, resolving the contradiction between texture quality and manufacturing ease.
2Productivity
If the embossing layer is not thoroughly removed, then the production process is faster, but the visual and tactile realism of the wood grain texture deteriorates
Solution Approach 1:
The pretreatment agent is applied in advance to modify the embossing layer properties, enabling complete removal without slowing down the production process. This preliminary modification ensures both high productivity and realistic texture quality.
Solution Approach 2:
The pretreatment agent acts as an intermediary substance that facilitates the removal of the embossing layer. It mediates between the embossing layer and the removal process, enabling thorough elimination of the embossing layer while maintaining production speed.
3Device complexity
If mechanical removal methods are used without pretreatment, then the process is simpler, but the embossing layer residue causes poor edge sharpness and alignment accuracy
Solution Approach 1:
The pretreatment agent changes the physical parameters of the embossing layer (viscosity and hardness), making it susceptible to complete mechanical removal. This parameter change enables achievement of sharp edges and accurate alignment without adding complex process steps.
4Speed
If the embossing layer viscosity and hardness are not reduced, then the removal process is faster, but complete removal is difficult resulting in residual liquid affecting texture quality
Solution Approach 1:
The pretreatment agent is applied before removal to reduce embossing layer viscosity and hardness. This preliminary action prepares the material for fast and complete removal, ensuring both high removal speed and excellent texture quality without residuals.
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 effectively removes the embossing layer, achieving a fine and natural texture with clear 3D patterns and good decorative visual effect, enhancing the aesthetic quality of SPC flooring.
Implementation Method 1
the embossing layer is impregnated with a pretreatment agent
Implementation Method 2
a pretreatment agent is applied to the embossing layer to reduce its viscosity and hardness
Implementation Method 3
curing at least a portion of the resin solution on the surface of the pattern layer to form a wood grain base layer
Implementation Method 4
the embossing solution and/or at least a portion of the resin solution mixed with the embossing solution form an embossing layer
Implementation Method 5
removing the embossing layer, thereby forming a three-dimensional wood grain layer on the surface of the wood grain base layer
Data Source
Figure 1~2
AI summary
The present invention belongs to the technical field of 3D printed panels, and specifically relates to a printed panel whose patterned surface has a three-dimensional wood grain effect and a method for its preparation. The invention introduces an additional pretreatment step, so that after the resin on the surface of the wood grain base layer is cured, the viscosity and/or hardness of the embossing liquid and/or the portion of the resin mixed with the embossing liquid and/or at least a part of the resin covered by the embossing liquid are reduced, effectively improving the problem of incomplete removal of the embossing layer by the steel brush roller. As a result, a three-dimensional wood grain structure is formed on the surface of the pattern layer, which has fine and natural texture, clear 3D patterns, accurate alignment, good visual decorative effect, sharp wood grain edges, and realistic tactile feel. By adding a post-treatment step after the embossing layer is removed, the residual embossing liquid and/or the portion of the resin mixed with the embossing liquid and/or at least a part of the resin covered by the embossing liquid are effectively removed, further enhancing the product quality of stone-plastic flooring with 3D wood texture.