Decorative Panel Top Coating for Natural Stone-Like Texture
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Solution Overview
Problem
Decorative panels made from synthetic materials often lack a natural feel and appearance, particularly in imitating materials like natural stone, limestone, sandstone, or concrete, despite advancements in decorative print quality.
Innovation Solution
Incorporating a texturizing agent with a distinct property from the coating material, such as a micro-granulate with a median particle diameter of 1 to 30 μm, into the top coating of decorative panels, combined with a relief in the top layer, to create a textured surface that mimics the feel and appearance of natural materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If embossed structures are used in the top layer, then visual appearance is improved, but tactile feel and authenticity deteriorate
Solution Approach 1:
The patent introduces a texturizing agent comprising particles with specific physical properties (median diameter 1-30 μm, BET surface area 200-500 m²/g) into the top coating layer. These particles create a porous, micro-rough surface structure that provides both visual appeal and authentic tactile feel resembling natural materials like stone or concrete, resolving the contradiction between visual appearance and tactile authenticity.
Solution Approach 2:
The patent creates a composite top coating by combining coating material with texturizing agent particles. This composite structure integrates the smoothing effect of the coating material with the texture-providing particles, achieving both good visual appearance and authentic tactile feel that neither component could achieve alone.
2Stability of the object's composition
If smooth top coating is applied, then visual uniformity is improved, but natural texture and feel deteriorate
Solution Approach 1:
The patent applies local quality by introducing texturizing particles specifically in the top coating layer while maintaining uniform distribution. The particles create localized micro-roughness (primary microrelief) that provides natural texture and feel, while the overall coating remains visually uniform and smooth at the macro level, resolving the contradiction between visual uniformity and natural texture.
3Ease of manufacture
If traditional embossing is used, then manufacturing simplicity is maintained, but authenticity and perceived quality deteriorate
Solution Approach 1:
The patent changes the physical parameters of the top coating by incorporating particles with specific median diameters (1-30 μm) and surface areas (200-500 m²/g). This parameter modification transforms the coating from a simple smooth layer to one with controlled micro-roughness, achieving authentic texture and feel while maintaining compatibility with existing coating application processes.
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 combination provides a more authentic and natural feel and appearance, enhancing the perceived quality of the panels before and after installation, with a convincing illusion of small particles being released, improving the overall aesthetic experience.
Implementation Method 1
the texturizing agent may for example be a granular material, which may be suspended in the liquid coating material
Implementation Method 2
said coating material comprises a UV-curable lacquer
Data Source
AI summary
Decorative panel comprising a substrate and a top layer, wherein said top layer optionally is provided with a main surface top coating provided thereon and said decorative panel at at least one upper edge is provided with a lowered edge region, wherein at least a portion of said lowered edge region is provided with a lowered edge top coating, wherein said lowered edge top coating is transparent or translucent.