Composite Surface with Embedded Particulate Graphite
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Solution Overview
Problem
Traditional composite products, such as laminate panels, often lack the aesthetic appeal of natural materials like wood and stone due to their synthetic appearance, particularly in terms of texture and thermal conductivity, which can be identified by touch.
Innovation Solution
A method involving a sheet-form curable material with embedded surface effect materials, such as particulate graphite for enhanced thermal conductivity, is applied to a substrate to create a simulated stone surface, where the surface effect material is embedded in the skin during the moulding process, and optionally treated to increase exposure, such as through sandblasting, to mimic the feel and appearance of natural stone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If synthetic materials are used to replace natural materials, then cost and manufacturing advantages are improved, but aesthetic appeal and tactile realism deteriorate
Solution Approach 1:
The patent applies composite materials by combining synthetic foam substrate with natural or synthetic particulate surface effect materials (such as stone chips, sand, or granules) embedded in a curable skin layer. This creates a multi-layer composite structure where the foam provides manufacturing advantages while the particulate surface layer delivers natural material aesthetics and tactile properties, effectively resolving the contradiction between ease of manufacture and aesthetic appeal.
Solution Approach 2:
The patent applies local quality by differentiating the properties of different layers: the foam substrate maintains uniform synthetic properties for manufacturing efficiency, while the surface skin layer incorporates varied particulate materials to locally replicate the specific aesthetic and tactile characteristics of natural materials like stone or wood. This localized application of different material qualities allows each layer to optimize its function.
2Device complexity
If smooth synthetic surfaces are used, then manufacturing simplicity is improved, but thermal conductivity and tactile realism deteriorate
Solution Approach 1:
The patent applies porous materials by incorporating particulate fillers (stone chips, sand, granules) within the curable skin layer that creates a porous or heterogeneous structure. This structure increases thermal conductivity compared to smooth synthetic surfaces by providing thermal pathways through the particulate network, while also delivering realistic tactile properties that mimic natural materials. The porosity and particle distribution enable heat transfer more effectively than homogeneous smooth surfaces.
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 produces composite products with improved thermal conductivity and a realistic stone surface texture, addressing the tactile and visual discrepancies between synthetic and natural materials, enhancing the overall aesthetic and sensory experience.
Implementation Method 1
a sheet-form curable material, wherein the sheet-form curable material is at least partially cured and is bonded to the substrate and the surface material is embedded in an exposed surface of the sheet-form curable material
Data Source
Figure 1~2
Figure 3
Figure 4a~4b
AI summary
The present invention relates to methods of manufacturing composite products having a surface effect. In some examples described, a composite product has a simulated surface, for example a stone-effect surface formed by pressing a particulate-form surface material (30) and a sheet-form curable material (40) onto a substrate (44) having an open-celled structure. In other examples, a laminate product having a veneer is formed by pressing a veneer and a sheet-form material onto a substrate including a porous structure. The veneer may comprise a wood material. In other examples, a surface effect material is bonded to a skin by pressing a sheet-form curable material to a mould surface and the surface effect material. Where the surface effect material has a high thermal conductivity, the composite product formed can feel cool to the touch.