Decorative Panel Protective Layers for Deep Wear-Resistant Relief
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Solution Overview
Problem
Existing methods for manufacturing decorative panels with printed motifs face challenges in achieving flexible and durable structures that protect against wear and moisture, with hard particles in top layers affecting material viscosity and flow, and limited depth and depth-to-width ratios of digital structures.
Innovation Solution
A method involving a two-layer protective structure where a first finishing layer with hard particles is applied, followed by a second finishing layer free of hard particles, allowing for the formation of recesses with surface-altering agents, such as chemical agents or thermally expandable microspheres, to create durable and flexible relief patterns that correspond to the printed motif.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hard particles are included in the top layer to enhance wear resistance, then wear resistance is improved, but the material viscosity and flow are adversely affected
Solution Approach 1:
The top layer is divided into two separate finishing layers: a first finishing layer containing hard particles for wear resistance, and a second finishing layer without hard particles that allows proper material flow and viscosity control. This segmentation resolves the contradiction by isolating the hard particles to only the layer where they are needed for wear resistance, while the second layer maintains manufacturability.
2Adaptability or versatility
If digital printing techniques are used to create structures on panels, then flexibility is improved, but the depth and depth-to-width ratio of structures are limited
Solution Approach 1:
The patent transitions from two-dimensional digital printing to three-dimensional surface structures by forming recesses and relief patterns in the second finishing layer. This dimensional change allows the creation of deeper, more varied structures while maintaining the flexibility of digital printing techniques for pattern design.
3Device complexity
If a single-layer protective structure is used, then device complexity is reduced, but wear resistance and moisture protection are insufficient
Solution Approach 1:
The protective top layer is segmented into two distinct finishing layers, each with specific functions. The first layer provides wear resistance through hard particles, while the second layer provides moisture protection and allows for structural relief patterns. This segmentation improves reliability without significantly increasing complexity.
Solution Approach 2:
The top layer uses a composite structure combining two different finishing layer materials with distinct properties. The first finishing layer contains hard particles embedded in a matrix, while the second finishing layer has different compositional characteristics optimized for moisture barrier properties and relief formation, creating a composite material system that delivers superior overall performance.
4Ease of manufacture
If existing structuring techniques are used to create relief patterns, then manufacturing simplicity is maintained, but the structures do not correspond well to the printed motif
Solution Approach 1:
The second finishing layer is applied with locally varying properties to match the printed motif. By controlling the application and curing of the second finishing layer, recesses are formed specifically in areas corresponding to the printed design, creating local quality variations that make the relief structures correspond precisely to the motif while maintaining manufacturing simplicity.
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 creation of panels with enhanced wear resistance and deeper, more varied recesses, providing a smoother and more economical manufacturing process while maintaining the integrity of the printed design.
Implementation Method 1
the aforementioned first finishing layer comprises hard particles that protrude above the surface of the first finishing layer
Implementation Method 2
surface-altering agents, such as chemical agents or thermally expandable microspheres
Implementation Method 3
surface-altering agents, such as chemical agents or thermally expandable microspheres
Implementation Method 4
a transparent or translucent protective layer formed there above
Data Source
Figure 1~3
Figure 4~8
Figure 9~11
AI summary
Method for manufacturing panels, wherein these panels (1) comprise at least a substrate (2) and a decorative top layer (3), wherein the aforementioned decorative top layer (3) comprises at least a printed motif and a transparent or translucent protective layer (9) formed there above, and wherein the method comprises at least the following steps: - the step of providing a substrate; - the step (S3) of applying a first finishing layer (6) for forming a first portion of the aforementioned protective layer (9); - the step (S7A-S8A) of forming recesses (16) at the surface (15) of the aforementioned first finishing layer (16); - the step (S6) of applying a second finishing layer (7) for forming a second portion of the aforementioned protective layer (9); - the step of forming recesses (16) at the surface (17) of said second finishing layer (7).