Decorative Panel Laser Structuring for High-Resolution 3D Textures
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Solution Overview
Problem
Existing methods for producing decorative panels using laser structuring lack high resolution and throughput, limiting the precision and efficiency of introducing complex structures into the panels.
Innovation Solution
A method involving the application of a decorative layer, optional intermediate layer, and cover layer, followed by laser structuring using a matrix of partial beams generated by dividing a laser beam, modulated, and scanned onto the panel to create three-dimensional structures with high precision and adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional press plate method is used for texturing, then the process is simple, but the manufacturing precision and resolution of structures are limited
Solution Approach 1:
The patent replaces the mechanical press plate system with a laser-based structuring system. The laser beam is split into a matrix of partial beams that can be selectively guided onto the layer to be structured, eliminating the need for physical contact and enabling higher precision structuring without mechanical limitations.
Solution Approach 2:
The laser beam is divided into a matrix of multiple partial beams, allowing simultaneous structuring of multiple locations on the layer. This segmentation enables high-resolution patterning while maintaining process efficiency, as each partial beam can be independently controlled and positioned.
2Manufacturing precision
If laser treatment is used for structuring, then manufacturing precision is improved, but throughput and production efficiency are reduced
Solution Approach 1:
By splitting the laser beam into a matrix of partial beams, the system can structure multiple locations simultaneously rather than scanning point-by-point. This parallel processing approach maintains high precision while dramatically increasing throughput and production efficiency.
Solution Approach 2:
The patent combines multiple laser beams into a coordinated matrix that operates in unison on the layer. This merging of multiple beam operations into a single coordinated process enables high-speed structuring across large areas without sacrificing precision.
3Adaptability or versatility
If a single laser beam is used for structuring, then the process is simple, but the adaptability and versatility for different structures are limited
Solution Approach 1:
The single laser beam is segmented into a matrix of partial beams, each of which can be independently controlled and directed to different locations. This enables the system to create diverse and complex structures with high adaptability, as each beam can be modulated separately to form different patterns.
Solution Approach 2:
The system dynamically controls the matrix of partial beams, allowing real-time adjustment of beam positions, intensities, and patterns. This dynamic control provides versatile adaptability for creating various structures while maintaining a relatively simple base system architecture.
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
Enables high-resolution, high-throughput laser structuring for decorative panels, achieving realistic surface textures and designs with improved recyclability and cost-effectiveness while maintaining industrial production efficiency.
Implementation Method 1
splitting the laser beam into a matrix of a plurality of partial beams
Implementation Method 2
guiding the matrix of partial beams into a modulator for selectively inactivating individual partial beams
Implementation Method 3
guiding the matrix of partial beams from the modulator into an optical scanner
Implementation Method 4
the layer to be structured is negatively structured under the influence of the partial beams to produce a three-dimensional structure
Data Source
Figure 1
AI summary
The present invention relates to a method for manufacturing a decorative panel, comprising the process steps of: a) applying a decorative layer to a substrate, b) optionally applying an intermediate layer to the decorative layer, c) applying a top layer to the decorative layer or the intermediate layer, and d) structuring at least one layer (28) to be structured, wherein the layer (28) to be structured is selected from the decorative layer, the intermediate layer, and the top layer, characterized in that process step d) comprises the process steps of: d1) generating a laser beam (12); d2) splitting the laser beam (12) into a matrix (16) of a plurality of partial beams; d3) guiding the matrix (16) of partial beams into a modulator (24) for selectively inactivating individual partial beams;d4) Guiding the matrix (16) by partial beams from the modulator (24) into an optical scanner (26), wherein the matrix (16) by partial beams after the modulator (24) comprises all partial beams guided into the modulator (24) or a reduced number of partial beams; and d5) Guiding the matrix (16) by partial beams from the scanner (26) onto the layer (28) to be structured; wherein d6) the layer (28) to be structured is negatively structured by the action of the partial beams to generate a three-dimensional structure (34).