Decorative Panel Moisture Resistance via Lacquer Sealing

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Solution Overview

Problem

Decorative panels with thick wooden top layers face challenges in moisture resistance due to irregular edges and open pores, which can lead to moisture penetration and substrate swelling, making them difficult to clean and prone to discoloration.

Innovation Solution

The implementation of a decorative panel design featuring a wooden top layer with a continuous lacquer layer following the shape of open pores, a waterproof glue layer, water-repellent edges, and coupling mechanisms with precise clearances to create a tight connection, enhancing moisture resistance and ease of cleaning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If a thick wooden top layer is used to maintain natural appearance, then the aesthetic quality is improved, but moisture resistance deteriorates due to irregular edges and open pores

Engineering Contradiction:

Improvenatural appearanceVSAvoidmoisture resistance

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

A lacquer layer is applied over the wooden top layer to create a protective film that fills and seals the open pores and irregular edges. This flexible coating maintains the natural appearance while providing a moisture-resistant barrier that prevents water penetration to the substrate.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The panel combines multiple materials: the natural wood top layer for aesthetics, the lacquer coating for protection, and the waterproof glue layer for additional moisture barrier. This composite structure integrates the benefits of each material to achieve both appearance and moisture resistance.

Inventive Principle:

Principle #40Composite materials

2Shape

If open pores are left in the wooden top layer to maintain natural look, then the aesthetic quality is improved, but cleanability deteriorates as dirt collects in the pores

Engineering Contradiction:

Improvenatural lookVSAvoidcleanability

Core Design Contradiction:

ShapeVSEase of operation

Solution Approach 1:

The lacquer layer forms a smooth, continuous protective film over the open pores, creating a non-porous surface that repels dirt and is easy to clean. The underlying open pores remain visible through the transparent lacquer, maintaining the natural appearance while the surface becomes cleanable.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If a waterproof glue layer is applied to improve moisture resistance, then the protection against substrate swelling is improved, but the device complexity increases

Engineering Contradiction:

Improvemoisture resistanceVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The waterproof glue serves dual functions: it bonds the decorative top layer to the substrate and simultaneously acts as a moisture barrier. By combining the adhesive and waterproofing functions into a single layer, the structure remains relatively simple while achieving both objectives.

Inventive Principle:

Principle #5Merging (Combining)

4Shape

If edges are made irregular to allow natural wood appearance, then the aesthetic quality is improved, but moisture penetration increases through the edges

Engineering Contradiction:

Improvenatural appearanceVSAvoidmoisture penetration

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

The lacquer coating extends to the edges of the wooden top layer, creating a sealed border that prevents moisture from penetrating through irregular edge gaps. This maintains the natural appearance while blocking the harmful effect of moisture entry at the edges.

Inventive Principle:

Principle #30Flexible shells and thin films

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

This design significantly improves moisture resistance and cleanability of decorative panels, preventing substrate swelling and discoloration while maintaining a natural appearance, making them suitable for humid environments.

Implementation Method 1

said lacquer layer is continuous over the surface of said wooden top layer, and follows the shape of said open pores

Methodology Applied

Scientific EffectSurface tension: Surface Tension

Implementation Method 2

said decorative top layer is applied to said substrate by means of a waterproof glue and/or by means of a polyisocyanate based glue

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 3

at least one lateral edge of said wooden top layer has been provided with a water repellent agent

Methodology Applied

Scientific EffectHydrophobe: Hydrophobe

Data Source

PatentEP4119741A1Decorative panel

Publication Date: 2023.01.18 UNILIN BVBA

Figure 1~4
Figure 3
Figure 5

AI summary

Decorative panel, comprising a substrate (15) and a decorative top layer(16) having a thickness (T) of 1 mm or more, characterized in that said decorative panel (1) at at least two opposite edges (2-3;4-5) is provided with coupling means (6), wherein at the respective edges (2-3;4-5), in a coupled condition, the decorative top layers (16) laterally face each other with a clearance (23) in between, while the panels (1) are connected practically free from play or free from play.