Flat Decorative Element Manufacturing with Powder Layer
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Solution Overview
Problem
Existing methods for producing flat decorative elements, such as laminate floor panels, face challenges in creating a decorative design that is both efficient and effective in terms of product technology, particularly in achieving a durable and aesthetically pleasing surface with high abrasion resistance.
Innovation Solution
A method involving a carrier layer with a layer of powder applied and fixed through moistening and heat treatment, followed by digital printing of a decoration and a subsequent transparent wear-resistant cover layer, pressed together under high pressure and temperature to form a flat decorative element with a homogeneous, colored, and abrasion-resistant surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a dry powder layer is applied to a carrier layer and cured under heat and pressure to create a wear-resistant surface, then abrasion resistance is improved, but decorative design capability deteriorates
Solution Approach 1:
The patent applies preliminary action by first forming the wear-resistant powder layer and curing it to create a stable base surface, then subsequently applying the decorative print pattern and final clear coat. This sequential approach allows each layer to be optimized independently - the powder layer for abrasion resistance and the printed layer for decorative design.
Solution Approach 2:
The patent segments the surface treatment into distinct functional layers: a wear-resistant powder layer (containing aluminum oxide and binder) applied first, followed by a separate decorative printed layer. This segmentation allows the abrasion-resistant function and decorative function to be achieved through different material systems applied in sequence.
2Reliability
If wood fibers are mixed with thermosetting resin and compressed under high pressure and temperature to form a surface layer, then durability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes parameter changes by controlling the curing process of the thermosetting resin binder under specific heat and pressure conditions. The resin transitions from a liquid state during application to a solid cross-linked network structure during curing, providing durability while maintaining processability during manufacturing.
Solution Approach 2:
The patent employs composite materials by combining wood fibers with thermosetting resin to create a durable surface layer. The composite structure leverages the strength and durability of the resin-bonded wood fiber matrix while maintaining the aesthetic qualities of wood.
3Productivity
If multiple layers are pressed together in a short-cycle press to form the decorative element, then productivity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent merges multiple functional layers (carrier layer, powder layer with binder, decorative printed layer, and clear protective layer) into a single integrated decorative element through one pressing operation. This combining approach achieves high productivity by eliminating multiple separate pressing steps while the resin binder ensures precise bonding between layers.
Solution Approach 2:
The patent utilizes the phase transition of the thermosetting resin from liquid to solid during the pressing process. This phase change occurs under heat and pressure, causing the resin to cure and permanently bond the layers together in their pressed configuration, ensuring precision is locked in during the single pressing operation.
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 results in a decorative element with a colored homogeneous layer structure, high abrasion resistance, and flexibility, allowing for easy processing, with a wood content of over 40% and a thickness between 0.3 mm and 3.0 mm, suitable for applications like floor panels.
Implementation Method 1
The powder or the powder layer is then fixed on the carrier layer. This is preferably done by moistening the powder and then subjecting it to heat. This results in a pre-hardening, in which the powder of the powder layer is gelled. This results in cross-linking of the powder components on the surface of the powder layer.
Implementation Method 2
This results in a pre-hardening, in which the powder of the powder layer is gelled. This results in cross-linking of the powder components on the surface of the powder layer.
Implementation Method 3
The carrier layer, the powder layer and the decoration are then pressed to form the decoration element.
Data Source
Figure 1a~1m
AI summary
The invention relates to a method for producing a flat decorative element 1. For this purpose, a layer of powder 3 is applied to a carrier layer 2 and fixed in place. During the fixing of the powder layer, its surface is prepared so that it can be printed with a decorative design. The decorative design is then printed onto the fixed powder layer and dried. Optionally, a top layer is applied to the dried powder layer. The carrier layer 2, the powder layer, the decorative design, and the optional top layer are then pressed together in a press 14 to form the decorative element 1. The applied powder is a mixture of biomaterial particles, in particular wood particles, as well as color pigments, corundum, and thermosetting resins in powder form. Further aspects of the invention include a component with a decorative element 1 according to the invention and a method for producing a component using a decorative element 1 according to the invention.