Structured Surface Lacquer Curing via Absorber Film
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Solution Overview
Problem
The existing methods for producing structured surfaces on panel-shaped materials, such as wood-based panels, face limitations in variability and material loss due to the removal of uncured or partially cured paint sections, particularly when frequent changes in geometry are required for small lot sizes.
Innovation Solution
A two-stage curing method using a partially transparent film with a structured absorber layer, where the first curing step initiates crosslinking reactions based on radiation permeability, followed by a second curing step to complete the curing process, allowing for the creation of structured surfaces with indentations, elevations, and varying gloss levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If uncured or partially cured paint sections are removed to create surface structure, then surface structuring is achieved, but material loss occurs
Solution Approach 1:
The curing process is segmented into two distinct stages: first curing through the film creates a structured surface skin, then the film is removed and second curing completes the process. This segmentation allows the paint layer to be cured in sections rather than uniformly, enabling surface structuring without material removal.
Solution Approach 2:
The first curing step through the film is performed as a preliminary action to create the surface structure before the paint layer is fully cured. This preliminary curing of specific areas allows subsequent removal of the film and completion of curing in the second step, achieving structuring without losing paint material.
2Adaptability or versatility
If frequent changes to structuring geometry are required for small batch sizes, then variability is needed, but device complexity increases
Solution Approach 1:
The system uses a flexible film that can be dynamically repositioned, removed, and replaced with different films having various absorber layer structures. This dynamic approach allows frequent changes in structuring geometry without modifying the core curing apparatus, maintaining simplicity while achieving high variability.
Solution Approach 2:
Different films with varying absorber layer properties (thickness, material composition, pattern structures) are used to achieve different surface structuring outcomes. By changing the film parameters rather than the curing device parameters, the system achieves adaptability without increasing device complexity.
3Shape
If a film with absorber material is used for partial curing, then surface structuring is achieved, but complete curing requires an additional second curing step
Solution Approach 1:
The curing process continues uninterrupted through two stages: first curing through the film creates the surface structure, then after film removal, second curing completes the process. Both stages contribute usefully to the final product - the first creates structure and the first and second together achieve complete curing, eliminating idle time between essential curing actions.
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 the production of high-quality, durable surfaces with reduced material loss and increased variability in structuring, achieving complete curing and maintaining surface integrity while allowing for efficient production of high-gloss and matte finishes.
Implementation Method 1
a structured absorber layer is applied to the film before or after the application of the film by means of an absorber material that is at least partially opaque to radiation
Implementation Method 2
radiation is subsequently applied to the lacquer layer through the film in a first curing step, wherein, depending on the permeability of the structured absorber layer of the film, the lacquer layer is cured at least section by section and at least partially
Data Source
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AI summary
The invention relates to a method for producing a structured surface of a sheet-shaped material, in particular a wood-based panel, in which a lacquer layer is applied to the surface of the sheet-shaped material, in which a film that is at least partially transparent to radiation is placed on the lacquer layer, in which a structured absorber layer is applied to the film by means of an absorber material that is at least partially opaque to radiation before or after the application of the film, in which radiation is subsequently applied to the lacquer layer through the film in a first curing step, wherein, depending on the permeability of the structured absorber layer of the film, the lacquer layer is cured at least section by section and at least partially, in which the film is removed from the lacquer layer, and in which, in a second curing step, the lacquer layer is cured by means of radiation.preferably fully cured. The underlying technical problem is to further simplify the production of a structured surface on a sheet-like material. The invention also relates to a device for carrying out the process.