Glazed Panel Enamel Cavities for Sharp Decorative Filling
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Solution Overview
Problem
Existing methods for creating decorative enameled panels, such as those used in household appliances, face challenges with incomplete filling of engraved patterns due to the thick consistency and nature of filling materials, leading to a blurry aesthetic and reduced visual clarity, especially with thick enamel layers.
Innovation Solution
The development of an enameled panel with trapezoidal or substantially trapezoidal cavities in the enamel layer, filled with compatible inks or enamels, using LASER ablation for engraving and tempering before or after filling, ensures complete and precise filling without overflowing onto the enamel surface, enhancing the aesthetic quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional engraving methods are used to create decorative patterns on enameled panels, then the manufacturing process is simple, but the filling material cannot completely fill the engraved cavities due to its thick consistency, resulting in blurry outlines and poor aesthetic appearance
Solution Approach 1:
The engraved cavity is divided into multiple levels or steps, creating a segmented structure that facilitates complete filling. The cavity includes a first cavity portion and a second cavity portion at different depths, allowing the filling material to be applied in a controlled manner that ensures complete penetration and eliminates blurriness in the decorative pattern.
Solution Approach 2:
The invention transitions from a simple single-depth cavity to a multi-level cavity structure with varying depths. This dimensional complexity in the vertical direction enables the filling material to be contained and pressed effectively at different levels, ensuring complete filling while maintaining sharp pattern outlines.
2Shape
If thick enamel layers are used to achieve desired aesthetic effects, then the decorative appearance is enhanced, but the filling material even more incompletely fills the engraved motifs, worsening the blurriness
Solution Approach 1:
The multi-level cavity structure segments the thick enamel layer into manageable portions. By creating cavities at different depths (first and second cavity portions), the filling material can be effectively contained and pressed into each level, ensuring complete filling even when the total enamel thickness is significant, thereby maintaining sharp pattern outlines.
3Manufacturing precision
If multiple screen-printing operations with stencils are used to create decorative motifs, then precise pattern placement is achieved, but the process becomes time-consuming and difficult to implement
Solution Approach 1:
The invention merges the engraving and filling operations into a more integrated process. By creating multi-level cavities that are specifically designed to receive and contain the filling material, the need for multiple separate screen-printing operations with stencils is eliminated, streamlining the manufacturing process while maintaining pattern precision.
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 approach results in clear and aesthetically improved decorative patterns, even with thick enamel layers, by allowing for precise engraving and complete filling of cavities, thereby enhancing the overall visual clarity and aesthetic rendering of the panel.
Implementation Method 1
LASER ablation for engraving
Implementation Method 2
by LASER ablation, of engraving the enamel layer in successive transverse passes
Implementation Method 3
of carrying out a tempering of the panel before the step of filling the cavity or cavities, if the filling material or materials are or comprise one or more inks, or after the filling step if the filling material or materials are or comprise one or more enamels
Data Source
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AI summary
The present invention relates to a panel (1), and to a method of manufacturing such a panel (1), comprising a rigid support (2) comprising at least one surface (3 or 4) which is covered with at least one layer of enamel (5) comprising one or more cavities (6) made in all or part of its thickness and comprising at least one inner wall, said cavity(ies) (6) having a longitudinal section of trapezoidal or substantially trapezoidal shape, filled with one or more filling materials (9) which are, or comprise, one or more inks or one or more enamels.