Coated Panel Edge Finish and Coupling Design for Natural Chamfers
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Solution Overview
Problem
Existing coated panels with decorative top layers and chamfers exhibit unnatural glossy edges that detract from the imitation effect, and coupling mechanisms are prone to peaking and gap formation due to environmental changes.
Innovation Solution
The panels feature a lowered edge region with a lower degree of gloss than the central area, achieved by compressing or roughening the wearing layer, and utilize coupling means with flexible layers and water-repellent substances to minimize peaking and gap formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the wearing layer is left glossy on the lowered edge region, then the manufacturing process is simpler, but the edge region appears unnatural and the imitation effect is deteriorated
Solution Approach 1:
The patent applies a local quality change by reducing the gloss degree specifically in the lowered edge region while maintaining the original gloss in the central area. This is achieved through selective matting treatment (e.g., sanding, blasting, or chemical treatment) applied only to the lowered edge region, creating a visual distinction that mimics natural wear patterns and enhances the realism of the panel's imitation effect.
2Manufacturing precision
If the wearing layer is compressed or roughened to reduce gloss, then the depth effect and natural appearance are improved, but the manufacturing complexity increases
Solution Approach 1:
The patent changes the surface parameter (gloss degree) of the wearing layer in the lowered edge region through various methods such as mechanical compression, roughening treatments, or application of matting agents. This parameter change creates a visual depth effect that enhances the natural appearance, making the lowered edge region blend more realistically with the overall panel design.
3Device complexity
If coupling means are used without flexible layers, then the structure is simpler, but peaking and gap formation occur under environmental changes
Solution Approach 1:
The patent incorporates flexible layers within the coupling means to accommodate thermal expansion and contraction of the panels under environmental changes. These flexible elements allow the coupling mechanism to adapt to dimensional changes without causing peaking at the joints or forming gaps, thereby maintaining the integrity and stability of the assembled structure.
4Reliability
If water-repellent substances are applied to coupling means, then gap formation and peaking are reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies water-repellent substances as an intermediary layer on the coupling means or at the joint surfaces. This intermediary treatment prevents moisture ingress that could cause swelling or degradation of the coupling components, thereby reducing peaking and gap formation. The treatment can be applied through dipping, spraying, or coating methods during the manufacturing 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 the depth effect of the edge region and reduces peaking and gap formation, providing a more natural appearance and improved stability under environmental changes.
Implementation Method 1
the aforementioned wearing layer has, at the location of the lowered edge region, a lower degree of gloss than on the central area of the aforementioned coated panel... because the aforementioned wearing layer has a rougher surface structure at the location of the aforementioned lowered edge region than at the location of the overall surface and/or because the aforementioned wearing layer is compressed at the location of the aforementioned lowered edge region
Implementation Method 2
at least one portion of the surface of the coupling means is provided with a water-repellent substance
Data Source
AI summary
A coated panel with a substrate and a decorative top layer, such that the decorative top layer includes a print and a transparent wearing layer applied thereon. The panel has a lowered edge region at least on one edge. Both the aforementioned print and the aforementioned wearing layer extend continuously from on the central area of the panel over the aforementioned lowered edge region. The aforementioned wearing layer has a lower degree of gloss at the location of the lowered edge region than on the central area of the aforementioned coated panel and/or has a degree of gloss of 10 or less measured according to DIN 67530. A method for manufacturing is provided for the coated panel and to a milling tool applied therewith.