Fiber Cement Decorated Panel with Structured Film
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Solution Overview
Problem
Existing decorated wall and floor panels, particularly those based on wood materials, have limitations in fire safety and design variety, with mineral coverings offering improved fire resistance but limited decorative options, and existing methods for producing such panels can be improved for user applicability and haptic realism.
Innovation Solution
A decorated and surface-structured panel is created using a fiber cement board with a carrier plate, primer layer, decorative layer, radiation-curable varnish layer, structured plastic film, and topcoat layer, incorporating specific fiber materials and additives to enhance stability and manufacturability, and a method involving direct printing, radiation curing, and embossing to achieve a realistic haptic effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wood-based panels are used for decorative wall or floor panels, then decorative variety and tactile effect are improved, but fire resistance deteriorates
Solution Approach 1:
The patent applies composite materials by combining a fiber cement board (mineral-based, fire-resistant) as the core substrate with multiple decorative and protective layers including printed decorative layers, embossed plastic films, and radiation-curable lacquers. This composite structure allows the panel to achieve both the fire resistance of mineral materials and the decorative variety of wood-based panels, directly resolving the technical contradiction between fire safety and decorative versatility
2Object-affected harmful factors
If mineral wall or floor coverings are used, then fire resistance is improved, but decorative variety deteriorates
Solution Approach 1:
The invention creates a composite structure where the fiber cement board provides the fire-resistant mineral base, while additional layers (decorative print layers, embossed plastic films, and protective lacquers) are applied to achieve wood-like decorative effects and tactile sensations. This allows mineral coverings to overcome their traditional limitation in decorative variety while maintaining fire resistance
3Adaptability or versatility
If a surface texture is applied to improve realistic appearance, then haptic realism is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-embossing the plastic film with the desired surface texture (such as wood grain patterns) before applying it to the panel. This pre-structuring of the film simplifies the manufacturing process compared to creating textures directly on the finished panel, as the embossing can be done in advance using standardized embossing rollers or plates, thereby reducing overall manufacturing complexity while achieving high haptic realism
Solution Approach 2:
The plastic film serves as an intermediary carrier that can be independently embossed with complex surface structures before being applied to the panel. This intermediary approach allows the complex texturing operation to be separated from the main panel assembly process, making the manufacturing more manageable and enabling high haptic realism without proportionally increasing overall manufacturing complexity
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 provides improved fire properties and user applicability while offering a high level of stability and realistic haptic effects, addressing the limitations of existing panels and production methods by utilizing a fiber cement board and structured plastic film.
Implementation Method 1
A layer of radiation-curable lacquer arranged on the decorative layer
Data Source
Figure 1~3
Figure 4
AI summary
The present invention relates to a decorated and surface-textured wall or floor panel and a method for its manufacture. The invention proposes a decorated and surface-textured wall or floor panel (100) comprising a substrate (110) made of a fiber cement material, a primer layer (120) arranged on a surface of the substrate, a decorative layer (130) arranged on the primer layer, a layer (140) of a radiation-curable lacquer or hot melt arranged on the decorative layer, a structured plastic film (150) arranged on the layer of a radiation-curable lacquer or hot melt, and a topcoat layer (160) arranged on the structured plastic film.