Building Board Inkjet Coating for Wood-Like Appearance
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Solution Overview
Problem
There is a demand for building boards that closely resemble wood and present a three-dimensional appearance, which existing technologies have not adequately addressed.
Innovation Solution
A building board is created using an inorganic base material with wood board patterns, featuring an undercoat coating with a higher pigment content, an overcoat coating with a lower pigment content, and an inkjet coating with a different hue, along with a clear coating, to achieve a realistic wood-like appearance and enhanced weatherproofness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a wood grain pattern is formed on the surface of a building board, then the building board presents a wood grain design and appearance, but it does not present a three-dimensional appearance and does not closely resemble wood
Solution Approach 1:
The patent transitions from two-dimensional flat wood grain patterns to three-dimensional patterns by forming protrusions and recesses on the surface. The inkjet coating is applied at varying heights on these three-dimensional patterns, creating depth variation that mimics the natural three-dimensional structure of wood surfaces.
Solution Approach 2:
The inkjet coating applies different hues and pigment concentrations to different local areas of the wood board pattern. By varying the coating thickness and pigment content across different regions (protrusions vs. recesses), the patent creates local color variations that closely resemble natural wood grain characteristics.
2Manufacturing precision
If multiple coatings with different pigments and hues are applied, then the building board presents infinite gradation of density and hue variations, but the manufacturing process becomes more complex
Solution Approach 1:
The patent replaces traditional multi-layer coating mechanical application methods with inkjet printing technology. The inkjet system can precisely deposit varying concentrations of pigment and different hues in a single pass by controlling droplet placement and volume, eliminating the need for multiple separate coating operations and reducing overall process complexity.
Solution Approach 2:
The inkjet coating system dynamically adjusts parameters such as pigment concentration, coating thickness, and hue across different areas of the wood board pattern. By varying these parameters during a single coating operation, the patent achieves complex color gradations without requiring multiple coating layers or complex manufacturing equipment.
3Manufacturing precision
If the overcoat coating has varying position and thickness, then the wood board patterns present different depths of color, but controlling the coating uniformity becomes difficult
Solution Approach 1:
The inkjet coating system automatically adjusts its operation based on the three-dimensional surface topology. The varying thickness and position of the coating are self-determined by the interaction between the inkjet droplets and the protrusion-recess pattern, creating natural color depth variations without requiring complex manual control or sacrificing coating reliability.
Data Source
AI summary
A building board includes an undercoat coating, an overcoat coating having lower pigment content than the undercoat coating and having different hue from the undercoat coating and having variations in position and thickness, an inkjet coating having different hue from the overcoat coating and is applying partially, and a clear coating successively formed on surface of inorganic base material having a plurality of wood board patterns. There also is provided a method for manufacturing a building board including the steps of applying an undercoat paint to surface of inorganic base material having a plurality of wood board patterns, applying an overcoat paint having lower pigment weight concentration than the undercoat paint and having different hue from the undercoat paint, scraping off a part of the applied overcoat paint before the overcoat paint cures, partially applying inkjet painting having different hue from the overcoat paint, and applying a clear paint.