Building Element Pressing With Elastic Sheets for Wood Veneer Embossing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The natural embossing of wooden surfaces, such as wood veneers, is often compressed during pressing, reducing its visual appeal and structure, and uneven pressure distribution can lead to incomplete curing of thermosetting binders, resulting in hazy or white-colored portions.
Innovation Solution
Using an elastic or formable sheet made of polymeric material between the wooden surface and a non-structured press surface, applying heat and pressure to uniformly distribute pressure and maintain or enhance the natural embossing, ensuring complete curing of the thermosetting binder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pressure is applied to adhere the wood veneer layer to the substrate, then the bonding strength is improved, but the natural embossing of the wood veneer layer is compressed and reduced
Solution Approach 1:
An elastic sheet is introduced as an intermediary between the press plate and the wood veneer layer. This elastic sheet deforms under pressure to conform to the embossed portions of the veneer, allowing uniform pressure distribution across the surface while preserving the natural embossing structure during the bonding process
2Shape
If a non-structured press plate is used, then the natural embossing is better preserved, but the pressure distribution becomes uneven causing incomplete curing of the thermosetting binder
Solution Approach 1:
The elastic sheet acts as a pressure-distributing intermediary that compensates for the non-structured press plate. It deforms to reach into embossed portions and applies sufficient pressure to ensure complete curing of the thermosetting binder in those areas, while the press plate itself remains non-structured to preserve the natural embossing
3Shape
If an embossed press plate is used to enhance the embossing, then the visual appeal is improved, but it requires a custom press plate for each design increasing manufacturing complexity
Solution Approach 1:
Instead of embossing the press plate to match the desired pattern, the invention inverts the approach by using a non-structured press plate combined with an elastic sheet that conforms to the natural embossing of the wood veneer itself, eliminating the need for custom embossed press plates for each design
4Reliability
If high pressure is applied to ensure complete binder curing, then the curing reliability is improved, but the natural structure of the wood veneer is further compressed
Solution Approach 1:
The elastic sheet serves as a mediator that enables high pressure application while protecting the wood veneer structure. It distributes the high pressure uniformly across the surface and into embossed portions, ensuring complete binder curing without the localized compression that would occur with a rigid press plate
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 retains and sometimes increases the natural embossing of wood veneers, ensures uniform pressure distribution, and improves the curing of thermosetting binders, reducing hazy or white-colored portions.
Implementation Method 1
arranging an elastic sheet comprising a polymeric material between the wood veneer layer and a press surface of a pressing device, applying heat and pressure by the pressing device on the elastic sheet
Implementation Method 2
applying a thermosetting binder on the substrate or on a wood veneer layer... applying heat and pressure by the pressing device on the elastic sheet, the wood veneer layer, the thermosetting binder, and the substrate
Data Source
Figure 1~3
Figure 4
AI summary
The present disclosure relates to a method for producing a building element, including providing a substrate, applying a thermosetting binder on the substrate or on a wood veneer layer (3), arranging the wood veneer layer (3) on the substrate with the thermosetting binder intermediate the substrate and the wood veneer layer (3), arranging an elastic or formable sheet (5) including a polymeric material between the wood veneer layer (3) and a press surface (21) of a pressing device, applying heat and pressure by the pressing device on the elastic or formable sheet (5), the wood veneer layer (3), the thermosetting binder, and the substrate, thereby forming a building element including the substrate and the wood veneer layer (3) attached to the substrate by the thermosetting binder, after applying heat and pressure, removing the elastic or formable sheet (5) from the wood veneer layer (3). The disclosure also relates to a pressing device for embossing a wooden surface (12) and a method of embossing a wooden surface (12).