Digital Overlay Patterning to Reduce Wear-Resistant Particle Waste
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Solution Overview
Problem
Existing wear-resistant surface technologies for building panels, such as laminate floors, apply particles randomly, leading to uneven distribution, increased material usage, and higher wear on cutting tools due to unnecessary application on non-surface areas.
Innovation Solution
A two-step process where wear-resistant particles are applied and bonded in a predetermined pattern using a liquid binder, with non-bonded particles removed, allowing for precise distribution and application only where needed, reducing material usage and tool wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wear-resistant particles are applied randomly on the entire surface, then wear resistance is provided, but material usage increases and tool wear increases due to unnecessary application on non-surface areas
Solution Approach 1:
The patent applies wear-resistant particles selectively only to the raised portions of the embossed surface that will be visible after pressing, rather than uniformly across the entire surface. This local application approach maintains wear resistance where needed while reducing material consumption on areas that will be compressed into recesses
Solution Approach 2:
The patent applies the wear-resistant particles to the embossed pattern before the final pressing operation. This preliminary application allows the particles to be positioned on the raised portions before compression, ensuring they end up only on the visible surface areas after pressing, thereby avoiding waste on areas that will be compressed away
2Reliability
If wear-resistant particles are applied randomly on the entire surface, then wear resistance is provided, but manufacturing precision decreases due to uneven distribution
Solution Approach 1:
The patent creates a non-uniform distribution pattern where wear-resistant particles are concentrated on the raised portions of the embossed surface and absent from the recessed areas. This localized concentration achieves uniform visual appearance and consistent wear resistance across the visible surface without requiring random distribution over the entire area
Solution Approach 2:
By applying particles to the embossed pattern before pressing, the patent ensures precise positioning of particles on areas that will form the visible surface. This preliminary positioning action guarantees uniform particle distribution on the final visible surface, eliminating the unevenness that would result from random application
3Reliability
If wear-resistant particles are applied on areas that will be cut or milled, then wear resistance is provided, but tool wear increases
Solution Approach 1:
The patent restricts wear-resistant particle application to only those raised surface portions that will remain after cutting and milling operations. Areas designated for cutting, grooving, or milling are excluded from particle application, eliminating the harmful effect of particles on tool wear while maintaining wear resistance on the final visible surface
Solution Approach 2:
The patent applies wear-resistant particles to the embossed pattern before subsequent cutting and milling operations. This sequencing ensures that particles are present only on areas intended to remain, and are automatically excluded from areas that will be removed by cutting tools, thereby preventing tool wear without compromising wear resistance
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 enables a cost-efficient, precise application of wear-resistant particles, reducing tool wear and material costs by ensuring particles are evenly distributed and applied only where necessary, enhancing wear resistance and transparency.
Implementation Method 1
bonding a part of the wear resistant particles to the surface with the liquid binder
Data Source
AI summary
A method to form a protective overlay with wear resistant particles applied in well-defined patterns by applying wear resistant particles on a surface, bonding a part of the wear resistant particles with a binder preferably applied with a digital drop application head and removing the non-bonded wear resistant particles from the surface.