Natural Effect Panel with Irregular Surface via Carved Mould
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Solution Overview
Problem
Existing high-pressure laminate (HPL) technologies primarily focus on top surface design, lacking a natural effect and making it difficult to modify or add features once the laminate layer is formed, thus failing to replicate the appearance and feel of natural materials like stone or concrete.
Innovation Solution
A method involving layering a base resin-impregnated paper sheet, wood particles, and additional resin-impregnated papers, compressed with a carved mould under heat and pressure to create an irregular surface that imitates natural stone, marble, or concrete, extending the natural effect across the top, side, and edge of the panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If HPL is used as a sturdy cover material, then durability and resistance are improved, but the ability to create natural effects and modify surface features deteriorates
Solution Approach 1:
The patent applies preliminary action by incorporating the irregular surface pattern into the HPL material during its manufacturing process, before the laminate is applied to the furniture panel. This allows the natural effect to be pre-formed in the material itself, enabling both durability of HPL and natural aesthetic effect to coexist without requiring post-lamination modification
2Adaptability or versatility
If manual engraving or CNC carving is used to create surface features, then natural effect is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent uses a patterned roller that replicates the irregular surface pattern of natural materials (stone, concrete, wood) onto the HPL material. This copying approach creates realistic natural effects without requiring complex manual engraving or CNC carving operations, significantly reducing manufacturing complexity while maintaining aesthetic quality
Solution Approach 2:
The patent replaces complex mechanical carving systems (manual engraving tools or CNC machines) with a simpler pattern transfer mechanism using a patterned roller. This substitution maintains the natural surface effect while dramatically reducing device complexity and manufacturing cost
3Ease of manufacture
If HPL focuses on top surface design, then manufacturing simplicity is improved, but the natural effect across the entire panel deteriorates
Solution Approach 1:
The patent extends the irregular surface pattern from the traditional two-dimensional top surface to include the vertical sides and edges of the panel. The patterned roller applies the natural effect pattern across multiple dimensions of the HPL material, creating a comprehensive three-dimensional natural appearance that encompasses the entire panel structure
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 a high-quality panel with a realistic visual and tactile effect, capable of replacing actual materials like stone or concrete, while maintaining durability and aesthetic appeal, and meeting stringent performance tests for resistance and durability.
Implementation Method 1
compressed with a carved mould under heat and pressure
Implementation Method 2
compressed with a carved mould under heat and pressure
Data Source
AI summary
A method comprising layering a base layer; depositing a layer of wood particles on the base layer; dispersing the wood particles evenly within a frame; layering a paper sheet; compressing the wood particles with the paper sheets to obtain an enwrapped composite board; layering a kraft paper, a decorative paper and an overlay paper by sequence on the composite board, wherein the kraft paper, the decorative paper and the overlay paper are resin impregnated; and compressing the layered kraft paper, decorative paper and overlay paper to the top and side of the composite board with a carved mould under heat and pressure; thereby forming the natural effect panel that having an irregular surface from top to the side including edge of the panel.