Panel Manufacturing With Foil Curing for 3D Surface Structures
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Solution Overview
Problem
Existing methods for manufacturing panels with three-dimensional surface structures are expensive, rigid, and limited in design variety due to the use of embossing techniques, and require additional anti-wear particles that complicate the process.
Innovation Solution
A method involving the application of a curable substance between a substrate and an air-tight foil, where discrete quantities of an additional substance are applied away from the substrate, allowing for curing via radiation through the foil, followed by removal of the foil and additional substance to create a three-dimensional surface structure, eliminating the need for anti-wear particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If embossing plates or rollers are used to create surface structure, then a three-dimensional relief is obtained, but the manufacturing cost increases and design variety is limited
Solution Approach 1:
The patent replaces the mechanical embossing system (plates or rollers) with a chemical/curing-based system. A curable substance is applied to the substrate, then an air-tight foil is placed on top. Radiation curing through the foil creates the three-dimensional surface structure without requiring expensive embossing equipment, thereby reducing manufacturing costs while maintaining design flexibility.
Solution Approach 2:
The patent changes the state of the curable substance from liquid/soft to solid/cured through radiation exposure. This phase change enables the formation of three-dimensional surface structures. By controlling the curing parameters (radiation dose, foil permeability), various surface structures can be achieved without expensive embossing tools.
2Shape
If embossing plates or rollers are used to create surface structure, then a three-dimensional relief is obtained, but the device complexity and production rigidity increase
Solution Approach 1:
The complex mechanical embossing system is replaced with a simpler radiation curing process. The air-tight foil acts as a template that defines the surface structure, eliminating the need for complex embossing machinery. This substitution increases production flexibility as different foil designs can be used without changing mechanical equipment.
3Strength
If anti-wear particles are added to the foil, then abrasion resistance is improved, but the process complexity and production costs increase
Solution Approach 1:
The patent uses a disposable air-tight foil that is removed after curing. The foil itself provides the necessary surface structure definition without requiring additional anti-wear particles. This eliminates the complexity of incorporating and distributing particles while still achieving the desired surface properties through the curing process.
Solution Approach 2:
The patent extracts the anti-wear particles function from the system by relying on the cured curable substance itself to provide the necessary surface properties. The air-tight foil is completely removed after curing, leaving only the cured surface structure on the substrate without any foreign particles embedded in it.
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 creation of a strong, three-dimensional surface structure with enhanced abrasion resistance and design flexibility, reducing production costs and complexity while maintaining high-quality surface characteristics.
Implementation Method 1
Due to its air-tightness the foil functions as a barrier against oxygen transfer through the foil. This means that local inert conditions at the curable substance are created.
Implementation Method 2
subsequently curing at least a part of the layer of curable substance by means of radiation through the foil resulting in a layer of at least partly cured substance
Data Source
Figure 1~2
AI summary
A method of manufacturing a panel, comprising the steps of supplying a substrate (1), applying a layer of curable substance (3) onto the substrate (1), applying a substantially air-tight foil (6) onto the layer of curable substance (3) such that the layer of curable substance (3) is sandwiched between the substrate (1) and the foil (6), subsequently curing (8) at least a part of the layer of curable substance (3) by means of radiation through the foil (6) resulting in a layer of at least partly cured substance (3', 3"), characterized in that the method comprises a step of applying discrete quantities of an additional substance (5) at a side of the curable substance (3) which is directed away from the substrate (1) and in that after the step of curing (8) the foil (6) and the discrete quantities of an additional substance (5) are removed from the layer of at least partly cured substance (3', 3") so as to form the panel.