Decorative Surface Covering with Printed 3D Wood Embossing
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Solution Overview
Problem
Existing decorative surface covering elements, such as laminated panels, fail to optimally replicate the optical and haptic appearance of natural wood due to uniform embossing directions, leading to a glossy surface without visible print effect and potential deformation of the decorative layer.
Innovation Solution
A surface covering element with a core and a decorative top structure featuring a three-dimensional embossing structure, comprising a roughened texture achieved through mechanical treatment of partially cured embossing ink, and a multi-layer embossing structure with aligned indentations and elevations, enhanced by a finishing layer for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If mechanical impressions are used to create embossing structure, then a relief with smoothly curved boundaries is obtained, but the texture becomes too smooth and rounded, failing to mimic natural wood nerves with sharp edges
Solution Approach 1:
The patent replaces conventional mechanical impression systems with a printing system that deposits embossing material selectively. Instead of using mechanical rollers to press patterns into the surface, the invention uses print heads to deposit embossing ink or paste that forms three-dimensional relief structures with sharp, well-defined edges that accurately mimic natural wood nerve patterns.
Solution Approach 2:
The invention changes the physical state and deposition parameters of the embossing material. By controlling the viscosity, curing properties, and deposition precision of the embossing ink or paste, the system can create relief structures with precise dimensional control and sharp edges, transforming the embossing process from a mechanical deformation process to a controlled material deposition and curing process.
2Shape
If conventional mechanical embossing is used, then embossing structure is created, but the decorative layer becomes deformed and distorted, affecting its appearance
Solution Approach 1:
The patent segments the embossing function from the decorative layer by introducing a separate embossing material layer. The decorative layer remains intact and undistorted, while the embossing effect is achieved through a distinct material layer that is deposited on top of or integrated with the decorative layer, allowing independent optimization of both decorative quality and embossing effect.
Solution Approach 2:
The embossing ink or paste acts as an intermediary material between the decorative layer and the final embossed surface. This intermediate layer absorbs the embossing process, protecting the decorative layer from direct mechanical stress and deformation while still providing the desired three-dimensional relief effect.
3Adaptability or versatility
If liquid embossing ink is printed, then flexibility and design freedom are increased, but the ink flows easily after printing, creating a smoother texture than intended
Solution Approach 1:
The patent employs thixotropic agents in the embossing ink formulation that cause the material to exhibit time-dependent viscosity changes. The ink remains fluid during printing for easy deposition and design flexibility, then gradually increases in viscosity after printing to maintain the intended sharp edges and prevent flowing, achieving both design freedom and texture control.
Solution Approach 2:
The embossing ink undergoes a phase transition from a fluid state during printing to a more rigid state after deposition. This phase change, controlled by thixotropic properties or curing mechanisms, allows the material to be easily deposited in complex patterns while subsequently maintaining precise dimensional accuracy and sharp texture definition.
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 solution provides a more realistic wood-like appearance and improved tactile properties by creating sharp edges and deep embossing effects, while preventing deformation of the decorative layer and enhancing durability.
Implementation Method 1
the embossing ink used to build (at least a part of) the embossing structure to be thick or viscous under static conditions, wherein the viscosity of the ink will decrease upon exertion of mechanical pressure or force allowing the ink to flow and to be deformed more easily
Data Source
AI summary
The invention relates to a decorative surface covering element, in particular a floor panel, ceiling panel or wall panel. The invention also relates to a panel covering, such as a floor covering, ceiling covering or wall covering, including a plurality of panels. The invention further relates to a method of producing a decorative surface covering element.