Press Plate Surface Structure for Natural Wood Appearance
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Solution Overview
Problem
Conventional methods for manufacturing press plates fail to accurately apply surface structures with fine projections less than 1 mm, resulting in floor panels with depressed portions that lack the natural appearance and varied gloss levels of natural materials like wood.
Innovation Solution
A method involving etching and chrome treatments to create fine projections on the press plate surface, followed by precise application of surface treatment materials using digitally controlled printers, ensuring the projections have a higher gloss level than the surrounding surface, achieved through multiple etching steps and surface treatments like sand blasting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional techniques such as silk screen process are used to apply resistant material, then the process is simple and cost-effective, but the accuracy is insufficient for providing resistant material onto fine projections with width less than 1 mm
Solution Approach 1:
The patent replaces conventional mechanical application methods (silk screen process) with a digitally controlled printing system. This substitution enables precise deposition of resistant material onto fine projections with width less than 1 mm, achieving the required manufacturing precision while maintaining process simplicity through digital control.
2Shape
If the press plate surface is etched to create fine projections, then the natural appearance of floor panels is improved, but the surface roughness increases at surrounding areas
Solution Approach 1:
The patent applies local quality by creating fine projections with controlled surface roughness at specific locations on the press plate. The etching process is localized to projection areas, while surrounding areas maintain different roughness characteristics. This enables the floor panel to exhibit varied surface properties that mimic natural materials, with smooth depressed portions and textured surrounding areas.
3Strength
If chrome treatment is applied to increase hardness of surface structure, then the durability is improved, but the gloss level uniformity may be affected
Solution Approach 1:
The patent applies local quality by selectively applying chrome treatment to different areas of the press plate. The chrome layer is applied to fine projections to increase hardness and create higher gloss levels, while surrounding areas receive different treatment to maintain uniform gloss. This selective application ensures both durability improvement and gloss level control.
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
Enables the creation of floor panels with depressed portions that mimic natural materials, such as wood, by achieving a higher gloss level and varied roughness, enhancing the natural appearance of the panels.
Implementation Method 1
The fine projections are covered by an etching-resistant material, preferably printed onto the fine projections by a digitally controlled printer
Implementation Method 2
the fine projections are created on the press plate surface by etching the press plate surface adjacent to the intended locations of the fine projections
Implementation Method 3
An alternative surface treatment may be sand blasting
Data Source
Figure 1~2
Figure 3a~3h
AI summary
A method of manufacturing a press plate (1) for applying a surface structure onto a floor panel, wherein the press plate (1) includes a press plate surface (2), comprises the following steps: first fine projections (3) are created on the press plate surface (2), then the resulting fine projections (3) are covered by a surface treatment resistant material, and subsequently the press plate surface (2) including the resistant material is submitted to a surface treatment.