Structured Lacquer Panel With Adhesion Promoter Layer
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Solution Overview
Problem
Existing methods for producing decorative panels with structured lacquer surfaces face challenges in creating small, localized structures and precise alignment, which results in panels with either no structure or simple, non-individualized structures.
Innovation Solution
A panel comprising a structured lacquer surface is achieved by using a base panel with a melamine resin layer, an adhesion promoter layer, and a lacquer-containing top coat, where the adhesion promoter layer facilitates the attachment of the structured lacquer top coat, allowing for more precise and individualized structuring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If embossing tools are used to introduce structure directly into the lacquer layer, then a structured surface can be achieved, but forming small and locally limited structures is difficult and precise alignment with the decoration is problematic
Solution Approach 1:
The patent divides the structuring process into two independent stages: first applying the decoration layer with its printed pattern, then separately applying the structured lacquer layer. This segmentation allows each layer to be optimized independently - the decoration can be printed with high precision while the lacquer structure can be formed using simple embossing tools without requiring complex alignment mechanisms.
Solution Approach 2:
The patent transitions from attempting to align structures in the same plane (2D alignment problem) to stacking layers in the third dimension (3D layering). By applying the lacquer structure on top of the decoration layer rather than trying to align them laterally, the patent eliminates the alignment precision problem while maintaining manufacturing simplicity.
2Adaptability or versatility
If embossing tools are manufactured and replaced for each production series, then variations of structure can be realized, but small production series become comparatively uneconomical
Solution Approach 1:
The patent creates a universal lacquer layer that can serve multiple functions: it provides wear protection, introduces surface structure through simple embossing, and can be applied to any decoration design without requiring custom tools. The same lacquer layer and embossing process can be used across different production series, making the process economically viable for small batches while maintaining structure variation capability through different embossing patterns.
Solution Approach 2:
The patent enables structure variation by changing parameters of the lacquer layer itself (such as embossing depth, pattern density, or lacquer composition) rather than changing the entire embossing tool for each variation. This allows flexible adaptation to different decoration styles while using the same basic manufacturing process, maintaining economy even for small production series.
3Ease of manufacture
If no structure or only simple structures are applied to panels, then the manufacturing process is simplified, but the haptic properties and wear protection are reduced
Solution Approach 1:
The patent merges the protective function and the aesthetic function into a single integrated lacquer layer. This top coat simultaneously provides wear protection and introduces surface structure for improved haptic properties, eliminating the need for separate protective layers while maintaining manufacturing simplicity. The structured surface is formed directly in the lacquer layer during its application process.
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 approach simplifies the manufacturing process, enables more precise and individualized structuring, and allows for the production of panels with improved wear protection and haptic perception, matching the visual impression of the decoration.
Implementation Method 1
an adhesion promoter layer and a lacquer-containing top coat, wherein the melamine resin layer is disposed on a surface of the base panel, the adhesion promoter layer is disposed on the melamine resin layer and the lacquer-containing top coat is disposed on the adhesion promoter layer
Data Source
AI summary
The present disclosure relates to a panel comprising a structured lacquer surface, having a base panel, a melamine resin layer, an adhesion promoter layer and a lacquer-containing top coat, the melamine resin layer being provided on a surface of the base layer, the adhesion promoter layer being provided on the melamine resin layer and the lacquer-containing top coat being provided on the adhesion promoter layer, the lacquer-containing top coat being structured. The disclosure also relates to a method for producing a panel of this type with a structured lacquer surface.