Chamfered Decorative Panel Coating for Uniform Bevel Finish
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing decorative panels with beveled edges are costly to produce, require high manufacturing accuracy, and are prone to staining and damage, with visible color differences between the bevel and top surface.
Innovation Solution
A decorative panel design featuring a chamfered edge with a coating layer that seamlessly covers both the top surface and chamfer, providing protection and consistent gloss level, applied in a single manufacturing step, and optionally includes a wear layer to prevent staining and enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If digital printing is used to decorate the bevel surface, then the visual effect is enhanced, but the production cost increases and manufacturing accuracy requirements become very high
Solution Approach 1:
The patent merges the decoration process with the coating application by incorporating pigments directly into the coating layer that is applied to both the top surface and bevel surface. This eliminates the need for separate digital printing operations and reduces manufacturing complexity while achieving consistent visual appearance across all surfaces.
Solution Approach 2:
The patent applies the coating layer with integrated pigments to the bevel surface during the initial coating process, before any potential staining or damage can occur. This preliminary protective and decorative coating eliminates the need for subsequent expensive digital printing operations and provides immediate protection against staining.
2Shape
If the bevel surface is decorated separately, then the aesthetic appearance is improved, but color differences between the bevel and top surface become visible
Solution Approach 1:
The patent combines the decoration of the top surface and bevel surface into a single coating application process. The coating layer containing pigments is applied simultaneously to both surfaces, ensuring uniform color and pattern across all visible areas, thereby eliminating color differences that would result from separate decoration processes.
Solution Approach 2:
The patent achieves homogeneity in appearance by using a single coating layer with integrated pigments that covers both the top surface and bevel surface uniformly. This ensures that the color, gloss level, and overall aesthetic appearance are consistent across all surfaces, eliminating the color mismatches that occur with separate decoration methods.
3Ease of manufacture
If the chamfer is left unprotected, then the manufacturing process is simpler, but the chamfer becomes prone to damage and staining
Solution Approach 1:
The patent combines the protection of the top surface and chamfer into a single coating application step. The coating layer is applied to both surfaces simultaneously, providing comprehensive protection against damage and staining while maintaining manufacturing efficiency. This eliminates the need for separate protection processes for the chamfer.
Solution Approach 2:
The patent applies the protective coating layer to the chamfer surface during the initial coating process, before any staining or damage can occur. This preliminary protection ensures that the chamfer is resistant to staining and damage from the outset, eliminating the need for subsequent protective treatments.
4Reliability
If multiple separate coating steps are used for the top surface and chamfer, then each surface can be optimized, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent merges the coating of the top surface and chamfer into a single application process. The coating layer is applied simultaneously to both surfaces in one operation, maintaining consistent quality and protection while significantly improving manufacturing efficiency and reducing production time compared to multiple separate coating steps.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to decorative panel and a method for producing such panel. The panel according to the present invention comprises a core layer, and a decorative top layer attached to the upper core surface of said core layer. The panel further comprises at least one chamfer provided at at least one of said side edges, wherein the chamfer extends through at least part of the decorative top layer and/or through at least part of the core layer, and the panel comprises at least one coating layer.