Chamfered Decorative Panel Coating for Uniform Gloss
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Solution Overview
Problem
Existing decorative panels with chamfers face issues of high manufacturing costs, sensitivity to staining, and inconsistent gloss levels between the top surface and chamfers, requiring separate processes for coating that can lead to color differences and damage.
Innovation Solution
A decorative panel with a coating layer that seamlessly covers both the top surface and chamfers, providing a protective function and consistent gloss level, applied in a single manufacturing step, using a cured coating that can include additives for flexibility and visual enhancement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate coating processes are used for top surface and chamfers, then coverage is complete, but manufacturing complexity increases and gloss consistency deteriorates
Solution Approach 1:
The patent combines the coating of the top surface and chamfers into a single integrated coating process. The coating composition is applied to cover both the top surface and chamfered edges simultaneously, eliminating the need for separate coating operations. This merging of processes simplifies manufacturing while maintaining consistent gloss levels across all surfaces through uniform application conditions.
2Shape
If chamfers are bevelled to enhance visual effect, then aesthetics improve, but surface area increases making the panel more susceptible to staining
Solution Approach 1:
The patent applies a coating composition to the chamfered edges before staining can occur. This preliminary protective layer acts as a barrier against stains, preventing harmful substances from penetrating the porous chamfer surface. The coating is specifically formulated to provide stain resistance while maintaining the desired visual appearance of the bevelled edges.
3Manufacturing precision
If digital printing is used to decorate bevel surfaces, then color matching improves, but manufacturing cost increases and precision requirements increase
Solution Approach 1:
The patent uses a coating composition that contains pigments and dyes to replicate the decorative appearance on chamfers. Instead of complex digital printing equipment, the invention uses a chemically-based copying approach where the coating material itself carries the color and pattern information, transferring it uniformly to the chamfer surfaces through the coating process.
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 enhances durability, prevents staining, maintains consistent gloss levels, and reduces manufacturing complexity by integrating the coating process, ensuring a uniform visual appearance and improved resistance to abrasion and scratches.
Implementation Method 1
applying a coating upon the upper surface of the decorative top layer and the (upper) surface of at least chamfer such that a coating layer is formed which covers at least part of the upper surface of the decorative top layer and at least part of the (upper) surface of said chamfer
Data Source
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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.