Floor Panel Bevelled Edge Coating Method
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Solution Overview
Problem
Current methods for producing panels with beveled edges are inefficient, prone to contamination, and result in suboptimal aesthetic and structural quality due to separate coating processes, deformation risks, and high paint loss.
Innovation Solution
A method where oblong depressions with sloping flanks are machined or thermally introduced into a wood-based carrier plate before applying a decorative layer, allowing for direct coating and seamless extension of the decorative layer onto beveled edges, eliminating the need for reshaping and reducing moisture penetration risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate coating process is used for bevelled edges after panel division, then the decorative layer can be applied to the inclined surfaces, but contamination of panel tops occurs and the transition from surface to slope cannot be produced seamlessly
Solution Approach 1:
The patent applies the preliminary action principle by introducing oblong depressions with sloping flanks into the carrier plate BEFORE the decorative layer is applied. This allows the decorative layer to be applied in a single continuous process to both the upper side and the bevelled edges, eliminating the need for separate coating operations that cause contamination and discontinuous transitions.
Solution Approach 2:
The patent merges the coating of the upper surface and the bevelled edges into a single decorative layer application process. By forming depressions that expose the sloping flanks before coating, the decorative layer can continuously cover both the top surface and the edges in one operation, combining what were previously separate coating steps.
2Ease of manufacture
If directed spraying is used to coat bevelled edges, then the inclined surfaces can be coated, but the spraying devices easily get dirty and require frequent cleaning and servicing
Solution Approach 1:
The patent uses preliminary action by pre-forming the oblong depressions with sloping flanks in the carrier plate before the coating process. This allows the decorative layer to be applied by non-spraying methods (such as roller coating or dip coating) that do not require complex spraying devices, thereby eliminating the maintenance issues associated with spray equipment while still achieving complete coverage of the bevelled edges.
3Manufacturing precision
If transfer foil painting is used to coat bevelled edges, then the inclined surfaces can be coated with a uniform transition, but the process is expensive and entails high paint loss
Solution Approach 1:
The patent combines the coating of the upper surface and bevelled edges into a single decorative layer application step. The oblong depressions are formed such that when the decorative layer is applied to the upper side, it naturally extends over the sloping flanks of the depressions, achieving uniform transition without requiring expensive transfer foil processes or resulting in significant material loss.
4Shape
If embossing is used to soften and shape the edge of a coated panel, then the bevelled edges can be formed, but the carrier board may deform if moisture penetrates into joints and the hard brittle coating can be damaged
Solution Approach 1:
The patent applies preliminary action by forming the oblong depressions with sloping flanks in the carrier plate BEFORE the decorative layer is applied and cured. This ensures that the structural shape is established while the material is still workable, and the subsequent coating process simply follows the pre-formed geometry, avoiding the need for post-coating embossing that could damage the brittle decorative layer or allow moisture penetration.
5Shape
If large-format carrier boards are pressed with decorative paper to emboss beveled edges, then the edges can be shaped, but only small inclined surfaces with small depth can be achieved due to uneven pressing pressure distribution
Solution Approach 1:
The patent uses preliminary action by forming the oblong depressions with the desired depth and slope in the carrier plate before the coating and pressing operations. This pre-forming allows deep and large inclined surfaces to be created without relying on pressing pressure distribution, which is inherently uneven in large-format boards. The subsequent coating process simply conforms to the pre-established geometry, achieving both deep bevels and uniform quality.
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
Enables the production of high-quality panels with uninterrupted decorative layers on beveled edges, preventing moisture ingress and achieving deep bevels with improved aesthetic and structural integrity.
Implementation Method 1
a decorative layer, preferably a wooden decorative layer, is applied as a direct coating by applying paint to the upper side of a carrier plate made of wood material
Implementation Method 2
oblong depressions with sloping flanks are introduced into the carrier plate before applying the decorative layer
Implementation Method 3
oblong depressions with sloping flanks are introduced into the carrier plate by machining or thermally
Data Source
Figure 1a~1e
Figure 2~3
Figure 4
AI summary
The invention relates to a panel, in particular a floor panel, comprising a support board (1) fabricated from wood-based material, a decorative layer (3), preferably a wooden decorative layer, produced by coating a surface of the support board (1) with varnish, and connecting elements (4, 5) on the edges for connecting the panel (1.1, 1.2) to corresponding panels, wherein at least two parallel edges of the panel are provided with edge bevels (2.1', 2.2'). According to the invention, the decorative layer (3) extends seamlessly from the surface of the support board (1) to the edge bevels (2.1', 2.2') and covers the latter. The invention also relates to a method for producing such panels (1.1, 1.2). The method is characterized in that elongate depressions (2) with sloping flanks (2.1, 2.2) are made in the support board (1) before the decorative layer (3) is applied, wherein the flanks (2.1, 2.2) are intended to define edge bevels (2.1', 2.2) on the edges of the finished panels (1.1, 1.2), wherein the flanks of the depressions (2) are coated by applying varnish before the support board (1) is divided up, and wherein the support board (1) is divided up into the panel (1.1, 1.2) in the region of the elongate depressions (2).