Textured Panel Manufacturing Using Phase-Change Texturing Removal
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Solution Overview
Problem
Existing methods for creating textured surfaces require high mechanical power to remove solid texturing substances, risking damage to the cured curable substance and leading to wear of mechanical tools.
Innovation Solution
Perform a phase transformation of the texturing substance and/or its reaction product into a non-solid material, such as a fluid 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 texturing substance, then removal is achieved, but high mechanical power is required and risk of damaging cured curable substance increases
Solution Approach 1:
The patent changes the physical state parameter of the texturing substance from solid to liquid or gas phase through phase transformation. This allows removal without high mechanical power by utilizing fluid dynamics (suction, rinsing, blowing) instead of mechanical force, directly resolving the contradiction between ease of removal and power consumption
Solution Approach 2:
The patent applies phase transition by transforming the texturing substance from solid phase to liquid or gas phase. This phase change enables the texturing substance to be removed through non-mechanical means such as suction or evaporation, eliminating the need for high mechanical power while maintaining effective removal capability
2Ease of manufacture
If mechanical means are used to remove solid texturing substance, then removal is achieved, but mechanical tools are subjected to wear and require continuous substitution
Solution Approach 1:
By transforming the texturing substance to liquid or gas phase, the patent eliminates the need for mechanical contact during removal. This prevents wear on mechanical tools entirely, avoiding the need for continuous tool substitution and registration, thus resolving the contradiction between ease of manufacture and loss of time
Solution Approach 2:
The patent replaces the mechanical removal system with a phase-based removal system. Instead of using mechanical brushes or scrapers that suffer from wear, the invention uses phase transformation followed by suction, rinsing, or evaporation, which are non-mechanical or minimal-contact processes, thereby eliminating tool wear and substitution requirements
3Shape
If texturing substance remains solid during curing, then texture formation is achieved, but removal becomes difficult and risky
Solution Approach 1:
The patent employs phase transition after curing to transform the solid texturing substance into liquid or gas phase. This timing is crucial: the texture is formed when solid, but removal is facilitated after phase transformation. This resolves the contradiction by maintaining the texturing function during curing while enabling safe removal afterward without damaging the cured curable substance
Solution Approach 2:
The patent incorporates a preliminary phase transformation step between curing and removal. By preparing the texturing substance for phase change before the removal operation, the system ensures that the cured curable substance has already gained sufficient strength to withstand the removal process, thereby maintaining reliability while achieving easy removal
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
Facilitates easy removal of texturing substances, reducing the risk of damaging the cured curable substance and minimizing tool wear, while maintaining manufacturing quality.
Implementation Method 1
said phase transformation can comprise melting, evaporation or sublimation
Implementation Method 2
said phase transformation can comprise melting, evaporation or sublimation
Implementation Method 3
said phase transformation can comprise melting, evaporation or sublimation
Implementation Method 4
curing the curable substance and removing softer portion from the cured substance, said softer portion being caused by the texturing fluid
Data Source
AI summary
A method of manufacturing a panel including a textured surface may involve the following successive events. A substrate may be provided. A curable substance may be provided onto the substrate. Discrete quantities of a texturing substance may be applied onto the curable substance. At least a part of the curable substance may be cured. A phase transformation of at least one of the texturing substance and a reaction product of the texturing substance and the curable substance may be performed to obtain a non-solid material. The non-solid material may be removed from the cured part of the curable substance.