Method for producing a deep-matned panel of material with a concrete and stone structure
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Solution Overview
Problem
Existing methods for producing decorative surfaces on plate-shaped workpieces, such as furniture and flooring, fail to accurately replicate the natural appearance and feel of concrete and stone, while also lacking in mechanical and chemical resistance.
Innovation Solution
A method involving a carrier plate coated with a mineral-based composition, structured to mimic concrete or stone patterns, followed by physical drying and irradiation with UV varnish in the vacuum ultraviolet range to create a microfolded surface with deep gloss and enhanced resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If melamine resin coating is used to create decorative surfaces, then production efficiency and durability are improved, but the ability to replicate natural stone appearance and tactile properties deteriorates
Solution Approach 1:
The invention uses a composite coating system consisting of a base coat containing inorganic pigments and fillers (such as calcium carbonate, quartz sand) combined with a clear top coat. This composite structure allows the base coat to provide the stone-like appearance and texture while the top coat provides durability and protective properties, successfully combining aesthetic replication with functional performance.
Solution Approach 2:
The invention applies different coating compositions to different layers: the base coat contains inorganic materials for appearance replication, while the top coat is formulated for durability and protection. This local differentiation of material properties allows each layer to optimize its specific function, achieving both aesthetic accuracy and mechanical durability.
2Manufacturing precision
If cement concrete is used to achieve authentic concrete appearance and feel, then tactile perception and visual authenticity are improved, but mechanical strength and chemical resistance deteriorate
Solution Approach 1:
The invention creates a composite coating material that combines inorganic fillers (calcium carbonate, quartz sand, rock flour) with organic binders (acrylic resins, vinyl acetate). This composite structure replicates the appearance and texture of concrete while providing superior mechanical strength and chemical resistance compared to pure cement concrete.
Solution Approach 2:
The invention modifies the composition parameters of the coating material by incorporating specific ratios of inorganic fillers to organic binders, adjusting particle size distributions, and controlling film thickness. These parameter changes enable the coating to achieve concrete-like appearance while maintaining the durability and strength characteristics of synthetic materials.
3Strength
If polymer concrete is used to improve mechanical strength and chemical resistance, then durability is improved, but the ability to replicate authentic concrete texture and appearance deteriorates
Solution Approach 1:
The invention differentiates between the base coat and top coat functions: the base coat contains inorganic pigments and fillers specifically formulated to replicate concrete texture and appearance, while the top coat provides protective properties. This local quality differentiation ensures authentic appearance without compromising durability.
Solution Approach 2:
The invention uses a composite coating system where inorganic materials (calcium carbonate, quartz sand) are combined with polymer binders in specific ratios. This composite approach allows the coating to exhibit both the aesthetic properties of concrete and the mechanical durability of polymer materials, overcoming the limitations of pure polymer concrete.
4Manufacturing precision
If UV varnish is applied to create matte surface with anti-fingerprint effect, then tactile properties and aesthetic appearance are improved, but the complexity of the manufacturing process increases
Solution Approach 1:
The invention combines the decorative base coat and the protective top coat into a unified coating system that can be applied in sequence. The top coat is formulated to self-form a matte microfold structure upon drying, eliminating the need for separate UV irradiation equipment and processes, thus reducing manufacturing complexity while achieving the desired surface properties.
Solution Approach 2:
The top coat formulation contains specific ingredients that enable it to self-form a matte microfold structure during the drying process without requiring external UV irradiation equipment. This self-organizing property of the coating material simplifies the manufacturing process while still achieving anti-fingerprint and aesthetic properties.
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 produces surfaces with an authentic concrete or stone appearance and feel, offering improved resistance to abrasion, chemicals, and household agents, while maintaining mechanical durability and ease of cleaning.
Implementation Method 1
physically drying the coating compound to a cured mineral coating
Implementation Method 2
Irradiating the coating compound with radiation in the vacuum ultraviolet (VUV) spectral range such that a microfold with a structure depth of less than 5 μm is formed
Data Source
AI summary
The present invention relates to a method for producing plate-shaped workpiece panels with decorative surfaces, comprising the steps (A) providing a substrate panel, (B) coating the substrate panel with a coating compound, (C) structuring the coating compound, (D) physically drying the coating compound to form a cured mineral coating, (E) coating the mineral coating with a radiation-curing UV lacquer, and (F) irradiating the lacquer compound with radiation in the vacuum ultraviolet (VUV) spectral range such that a microfold with a structure depth of less than 5 µm is formed, as well as a plate-shaped workpiece panel.