Coated Panel Chamfer with Matte Edge for Natural Depth
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Solution Overview
Problem
Existing coated panels with decorative top layers and chamfers suffer from unnatural glossy edges that detract from the imitation effect, and coupling mechanisms are prone to gaps and peaking due to environmental changes and improper locking.
Innovation Solution
A coated panel design with a lowered edge region featuring a lower degree of gloss and a continuous print and wearing layer, combined with specific coupling means and manufacturing methods, including milling tools with controlled cutting processes, to create a visually appealing and structurally stable flooring solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a chamfer is formed by removing the top layer on the edge of the panel, then the edge structure is simplified and easier to manufacture, but the glossy appearance of the chamfer creates a false and adverse visual effect that detracts from the imitation quality
Solution Approach 1:
The patent applies a matte effect specifically to the lowered edge region (chamfer) while keeping the central area glossy, creating a local quality difference. This is achieved by reducing the gloss of the transparent top layer in the edge region to match or be lower than the print layer, eliminating the false glossy appearance while preserving the overall aesthetic quality of the panel.
2Manufacturing precision
If the print and wearing layer extend continuously over the lowered edge region, then the visual continuity and imitation effect are improved, but the glossy edge appears synthetic and disturbing
Solution Approach 1:
The patent creates a local quality difference by applying a matte effect to the lowered edge region while maintaining continuity of the print and wearing layer. The matte finish in the edge region causes light to scatter rather than reflect directly, making the edge appear naturally recessed rather than synthetic and glossy, thus eliminating the harmful visual effect while preserving structural continuity.
3Manufacturing precision
If a lower degree of gloss is applied to the lowered edge region, then the depth effect is enhanced and visual anomalies are reduced, but additional manufacturing steps are required
Solution Approach 1:
The patent changes the gloss parameter of the transparent top layer in the lowered edge region, reducing it to match or be lower than the print layer. This parameter change can be achieved through various methods including applying a matte coating, using a matte finishing agent, or adjusting the curing process to create a matte surface, thereby enhancing the depth effect and eliminating visual anomalies.
4Adaptability or versatility
If coupling means are provided on the edges of the panel, then the flooring assembly capability is improved, but gaps and peaking occur due to environmental changes and improper locking
Solution Approach 1:
The patent incorporates a flexible underlayer between the substrate and the coupling means that can compensate for environmental changes such as temperature and humidity variations. This underlayer acts as a cushion that absorbs expansion and contraction forces, preventing gaps and peaking at the coupling joints, thus maintaining locking integrity under varying environmental conditions.
Data Source
AI summary
A coated panel with a substrate and a decorative top layer, such that the decorative top layer includes a print and a transparent wearing layer applied thereon. The panel has a lowered edge region at least on one edge. Both the aforementioned print and the aforementioned wearing layer extend continuously from on the central area of the panel over the aforementioned lowered edge region. The aforementioned wearing layer has a lower degree of gloss at the location of the lowered edge region than on the central area of the aforementioned coated panel and/or has a degree of gloss of 10 or less measured according to DIN 67530. A method for manufacturing is provided for the coated panel and to a milling tool applied therewith.