Substrate-Free Decorative Surface with Relief Pattern
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Solution Overview
Problem
Substrate-free decorative surface coverings lack a relief-like appearance, resulting in a visually flat and uniform appearance, which cannot be enhanced by marbling with different colors without retaining a flat effect.
Innovation Solution
A process involving the manufacturing of a colored polymer-based sheet, cutting it into particles, depositing a pigment- and filler-free powder, and heat-treating them to form a substrate-free surface covering with a relief-like pattern, where unfused particles are embedded in a transparent or translucent polymeric matrix, providing a non-uniform arrangement for a 3D visual effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If substrate-free surface coverings are made using polymer particles of one color or different colors, then the covering presents a uniform or marbled appearance, but the visual aspect remains flat and lacks depth
Solution Approach 1:
The patent introduces a third dimension to the surface covering by embedding particles at different depths within the transparent polymer matrix. This dimensional variation creates a relief-like appearance effect while maintaining the substrate-free homogeneous structure, resolving the contradiction between uniform thickness and visual depth.
Solution Approach 2:
The patent applies local quality by creating regions with different particle concentrations and depths within the transparent matrix. The particles are distributed non-uniformly, with some particles embedded deeper than others, creating local variations in light reflection and refraction that produce the relief effect.
2Stability of the object's composition
If particles are agglomerated using heat and pressure to form homogeneous sheet, then substrate-free covering is achieved, but relief-like appearance cannot be obtained
Solution Approach 1:
The patent changes the processing parameters during heat treatment and pressing to prevent complete fusion of particles. By controlling temperature, pressure, and time parameters, particles are embedded in the transparent matrix without fully agglomerating, maintaining both homogeneous structure and relief appearance.
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 solution achieves a decorative surface covering with enhanced mechanical properties and a relief-like appearance, offering improved aesthetic appeal with discrete particles suspended in a transparent matrix, enhancing both mechanical resistance and visual depth.
Implementation Method 1
passed through a heating zone, compacted and welded under pressure
Implementation Method 2
heat treating said particles and said substantially pigment and filler-free powder and compacting them in a press
Data Source
Figure 1~2
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AI summary
The present invention relates to a process to manufacture a substrate-free decorative surface covering, having a relief-like pattern, comprising a non-uniform arrangement of unfused and discrete colored polymer-based particles (9, 10), said particles being obtained by the shredding of a polymer based sheet, and said particles being non- uniformly embedded in, and principally surrounded by, a substantially transparent or translucent polymeric matrix 12.