Textured Panel Surface Formation Using Phase-Change Residue Removal
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Solution Overview
Problem
Existing methods for creating textured surfaces in panels require significant mechanical power to remove non-solid materials during curing, risking damage to the cured substance and necessitating frequent replacement of mechanical tools due to wear.
Innovation Solution
A phase transformation step is introduced to convert the reaction product of the texturing substance and curable substance into a liquid or gaseous phase, allowing easier removal without mechanical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical means are used to remove solid reaction product from cured substance, then removal capability is achieved, but mechanical power consumption increases and risk of damaging cured substance increases
Solution Approach 1:
The invention applies phase transition by heating the solid reaction product to transform it into a liquid state. This phase change from solid to liquid enables the reaction product to be removed easily through suction or rinsing without requiring significant mechanical power, thereby resolving the contradiction between removal capability and energy consumption
Solution Approach 2:
The invention replaces the mechanical removal system with a thermal-chemical system. Instead of using mechanical means to remove solid reaction product, the process uses heating to melt the solid product followed by suction or rinsing to remove the liquid material, substituting mechanical action with thermal energy and fluid dynamics
2Ease of manufacture
If mechanical means are used to remove solid reaction product, then removal capability is achieved, but tool wear increases requiring frequent replacement
Solution Approach 1:
By transforming the solid reaction product into liquid phase through heating, the invention eliminates the need for mechanical contact during removal. The liquid material can be suctioned or rinsed away without wearing down mechanical tools, thereby maintaining tool durability and reliability
Solution Approach 2:
The invention substitutes mechanical removal tools with a thermal-processing-and-fluid-removal system. The heating step melts the solid product, and subsequent suction or rinsing removes the liquid without mechanical contact, eliminating tool wear and extending operational reliability
3Ease of manufacture
If mechanical means are used to remove solid reaction product, then removal capability is achieved, but risk of damaging cured substance increases
Solution Approach 1:
The invention uses phase transition of the reaction product (not the cured substance) to enable removal. By selectively melting the solid reaction product while keeping the cured substance intact, the process allows easy removal through suction or rinsing without mechanical contact that could damage the cured material
Solution Approach 2:
The invention replaces mechanical removal that could damage the cured substance with a selective thermal process followed by fluid removal. The heating step selectively melts the reaction product based on its lower melting point, and the subsequent suction or rinsing removes the liquid without mechanical contact, eliminating damage risk
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 reduces the risk of damaging the cured substance and minimizes tool wear by facilitating the removal of non-solid materials through suction or evaporation, enhancing manufacturing efficiency and quality.
Implementation Method 1
said phase transformation involving transforming any reaction product of the texturing substance and the curable substance into a liquid phase to obtain a non-solid material. For example, said phase transformation can comprise melting.
Implementation Method 2
The non-solid material may be removed by means of suction, rinsing, blowing away or the like.
Implementation Method 3
In an alternative embodiment, not forming part of the present invention, the reaction product may be transformed into a gaseous phase, being at least part of the non-solid material. In this case the at least one of the texturing substance and the reaction product may be evaporated to the gaseous phase.
Data Source
Figure 1~2
AI summary
A method of manufacturing a panel (1) including a textured surface, comprising the successive steps of: supplying a substrate (2), applying a curable substance (3) onto the substrate (2), applying discrete quantities of a texturing substance (5, 11) onto the curable substance (3), curing at least a part of the curable substance (3), performing a phase transformation of at least one of the texturing substance (5) and a reaction product (13) of the texturing substance (11) and the curable substance (3), preferably into a fluid phase, to obtain a non-solid material, and removing the non-solid material (3", 5', 13') from the at least cured part of the curable substance, hence forming the panel (1) including the textured surface.