Decorative Panel Laser Structuring With Multi-Beam 3D Texturing
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Solution Overview
Problem
Existing methods for producing decorative panels using laser structuring lack high resolution and throughput, limiting the efficiency and quality of the structuring process.
Innovation Solution
A method involving the application of a decorative layer, optional intermediate layer, and cover layer on a substrate, where a laser beam is split into a matrix of sub-beams, modulated, and guided by an optical scanner to structure one or more layers, enabling high-resolution three-dimensional structures with high throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser structuring is used to introduce structures into a layer, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The laser beam is divided into a matrix of multiple sub-beams using a beam splitter. Each sub-beam can independently structure different areas of the layer simultaneously, transforming a single-point sequential process into a multi-point parallel process, thereby improving throughput while maintaining precision
Solution Approach 2:
The patent transitions from single-beam sequential scanning to multi-beam parallel processing by arranging beams in a matrix configuration. This dimensional expansion of the beam structure enables simultaneous processing of multiple locations, resolving the contradiction between precision and productivity
2Device complexity
If a press plate is used to structure a layer, then device complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The patent replaces the mechanical press plate system with an optical laser beam system. This substitution eliminates the need for complex mechanical reliefs and pressing mechanisms, simplifying the device while achieving superior structuring precision through optical energy deposition
3Productivity
If laser beam is split into multiple sub-beams, then productivity is improved, but device complexity increases
Solution Approach 1:
The beam splitter creates multiple copies of the original laser beam, distributing them in a matrix pattern. This optical copying approach enables parallel processing of multiple areas simultaneously, improving throughput while the complexity is managed through optical rather than mechanical means
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 method allows for precise, high-quality, and efficient structuring of decorative panels with high throughput, achieving realistic haptic and visual structures similar to natural materials like wood or stone, while improving recyclability and reducing material thickness and costs.
Implementation Method 1
splitting the laser beam into a matrix of a plurality of sub-beams
Implementation Method 2
guiding the matrix of sub-beams from the scanner onto the layer to be structured
Implementation Method 3
the layer to be structured is negatively structured under the action of the sub-beams to produce a three-dimensional structure
Data Source
AI summary
The present disclosure relates to a method for producing a decorative panel, comprising the following method steps: a) applying a decorative layer to a substrate, b) optionally applying an intermediate layer to the decorative layer, c) applying a cover layer to the decorative layer or the intermediate layer, and d) structuring at least one layer to be structured, said layer to be structured being selected from the decorative layer, the intermediate layer and the cover layer, characterised in that method step d) comprises the following method steps: d1) generating a laser beam; d2) dividing the laser beam into a matrix of a plurality of sub-beams; d3) guiding the matrix of sub-beams into a modulator for selective inactivation of individual sub-beams; d4) guiding the matrix of sub-beams from the modulator into an optical scanner, the matrix of sub-beams downstream of the modulator comprising all the sub-beams guided into the modulator or a reduced number of sub-beams; and d5) guiding the matrix of sub-beams from the scanner onto the layer to be structured; d6) the layer to be structured being negatively structured under the action of the sub-beams in order to generate a three-dimensional structure.