Decorative Panel Molded Polymer Grout Lines
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Solution Overview
Problem
The manufacturing of decorative panels with indented patterns is often expensive, labor-intensive, and time-consuming, making them less viable as alternatives to traditional tile installations.
Innovation Solution
A decorative panel comprising a backing layer with a relief decorative layer formed by polymerizing a base polymer and an overlay polymer, which can simulate grout lines or textures, is manufactured using a panel mold with ridges and recesses, allowing for efficient application and polymerization of the polymers to create a cost-effective and quick production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional tile installation methods are used, then realistic tile appearance is achieved, but installation cost and time increase
Solution Approach 1:
The patent creates a decorative panel that copies the appearance of multiple tiles and grout lines into a single panel unit. The relief decorative layer replicates the visual characteristics of tiled surfaces, allowing one panel to substitute for multiple individual tiles while maintaining realistic appearance.
Solution Approach 2:
The patent merges multiple tile and grout line elements into a single integrated panel structure. The backing layer with relief decorative layer combines what would traditionally be separate tiles and grout into one unified component, reducing installation complexity and time.
2Shape
If cutting tools are used to create indented lines in plastic resin, then grout line patterns are formed, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces mechanical cutting tools with a chemical/mold-based approach. Instead of using routers or cutting tools to create indented lines, the invention uses a mold with raised ridges that form the indented patterns through polymerization, eliminating complex mechanical machining operations.
Solution Approach 2:
The patent performs the pattern formation action in advance during mold preparation. The ridges are pre-formed on the mold surface, so when polymer is applied and cured, the indented patterns are automatically created without requiring subsequent machining or cutting operations.
3Shape
If tubular heaters are used to create indented lines in plastic resin, then grout line patterns are formed, but manufacturing time and energy consumption increase
Solution Approach 1:
The patent replaces thermal processing with mold-based polymerization. Instead of using tubular heaters to thermally form indented lines, the invention uses a pre-formed mold with ridges that creates the patterns during polymer curing, eliminating lengthy heating and cooling cycles.
Solution Approach 2:
The patent changes the fundamental parameter of pattern formation from thermal processing to mold-based chemical polymerization. This parameter change transforms a time-intensive thermal process into a faster curing process that occurs as part of the normal polymerization cycle.
4Shape
If ink and liquid top coat are used to create valleys on hardboard, then patterns are formed, but manufacturing precision and material consistency decrease
Solution Approach 1:
The patent uses a homogeneous polymer material throughout the decorative panel. Instead of applying different materials (ink, liquid top coat) that can vary in consistency and adhesion, the invention uses a single polymer base that is molded with integrated relief features, ensuring uniform material properties and consistent pattern formation.
Solution Approach 2:
The patent creates a composite structure with a backing layer and a relief decorative layer made of polymer materials. This composite approach provides both structural integrity and consistent decorative patterns, overcoming the limitations of applying multiple separate coating layers to hardboard.
5Shape
If multiple separate layers are used to create relief decorative effects, then decorative complexity increases, but manufacturing cost and time increase
Solution Approach 1:
The patent merges the backing layer and relief decorative layer into a single integrated polymer structure. The relief decorative layer is formed as part of the same polymerization process that creates the backing layer, eliminating the need for separate manufacturing and assembly steps for multiple layers.
Solution Approach 2:
The patent performs the relief decorative layer formation in advance during the initial polymerization process. The mold ridges create the relief patterns as the polymer cures, so the decorative effect is built-in during manufacturing rather than requiring subsequent layer application or assembly operations.
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 enables the production of decorative panels that are inexpensive, easy to manufacture, and fast to produce, while maintaining a realistic tile or stone appearance, thus offering a cost-effective alternative to traditional tile installations.
Implementation Method 1
the overlay polymer and the base polymer are polymerized together to define an integral structure
Data Source
AI summary
There is provided a decorative panel comprising: a backing layer having a back face for abutting a panel-receiving surface and a front face opposite to the back face; a relief decorative layer attached to the front face of the backing layer and comprising: a layer of a base polymer attached to the front face of the backing layer and substantially covering the front face of the backing layer; and a relief element made of a layer of an overlay polymer attached to the layer of base polymer and covering a portion thereof.