Multi-layer Embossing for Realistic Wood Grain Depth
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Solution Overview
Problem
Existing decorative panels with embossing techniques fail to achieve an optimal imitation effect of wood patterns, particularly when viewed at small angles, as they produce a glossy surface with minimal perceived print effect due to light refraction through the transparent layer.
Innovation Solution
A multi-layer embossing structure is implemented, comprising a base layer with indentations and an elevated pattern layer, where the indentations and elevations are strategically positioned to create a more realistic and deep embossing effect, enhancing the perceived depth and color visibility of the décor image, and can be aligned in register with the décor image to achieve a realistic and artistic design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple embossing structure with impressions extending in one direction is used, then the manufacturing process is simple, but the imitation effect of wood patterns is not optimal and the depth effect is insufficient
Solution Approach 1:
The embossing structure is divided into multiple independent layers: a base layer with first indentations and a second layer with second indentations. Each layer can be manufactured separately and then combined, allowing complex three-dimensional patterns to be achieved through simple, manageable manufacturing steps while maintaining high imitation quality.
Solution Approach 2:
The invention transitions from a single-layer two-dimensional embossing pattern to a multi-layer three-dimensional structure. By stacking multiple embossing layers with different indentation patterns, the patent creates depth effects and realistic wood grain appearances that cannot be achieved with simple single-layer embossing, thereby improving imitation quality without significantly complicating the manufacturing process.
2Reliability
If a transparent layer is used to protect the decorative layer, then the decorative pattern is preserved, but light refraction creates a glossy surface effect that reduces the visibility of the print at small viewing angles
Solution Approach 1:
The embossing structure introduces local variations in surface topology with multiple layers of indentations creating micro-shadows and depth variations. This local structural complexity causes light to scatter and reflect from different angles, allowing the print to remain visible even when viewed at small angles, while the transparent protective layer maintains its protective function.
Solution Approach 2:
The multi-layer embossing creates curved and angled surfaces rather than flat impressions. The three-dimensional undulating structure with overlapping layers generates multiple light reflection paths, reducing the glossy uniform appearance and enhancing print visibility across different viewing angles while preserving the protective transparent coating.
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 multi-layer embossing structure provides a more pronounced and realistic appearance, improving light effects and depth perception, making the décor image more aesthetically appealing and realistic, similar to real wood or tile patterns.
Implementation Method 1
a light refraction at the transparent layer of synthetic matter is created, as a result of which only a glossy surface can be seen
Data Source
Figure 1a~1e
Figure 2a~2b
Figure 3
AI summary
The invention relates to a decorative panel, in particular a floor panel, ceiling panel or wall panel. The invention also relates to a panel covering, such as a floor covering, ceiling covering or wall covering, comprising a plurality of panels according to the invention. The invention further relates to a method of producing a decorative panel according to the invention.