Structured Layer Curing via Variable Masking Thickness

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Solution Overview

Problem

Existing methods for producing workpieces with structured layers, such as wood-like decorations, are limited by the inflexibility of embossing tools and require additional processing steps for edge chamfering or rounding.

Innovation Solution

A method involving a support member with a liquid and curable layer, where a masking agent is applied in varying thicknesses to control curing, and uncured material is removed to create a structured layer with a height profile, thereby eliminating the need for separate edge processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If an embossing tool is used to create wood structures, then the layer obtains haptically perceptible wood structures, but the design flexibility is limited to the pattern on the embossing tool

Engineering Contradiction:

Improvestructured layer shapeVSAvoiddesign flexibility

Core Design Contradiction:

ShapeVSAdaptability or versatility

Solution Approach 1:

The patent changes the parameter of structure creation from mechanical embossing to controlled curing through masking. By varying the masking agent layer thickness (parameter change), different height profiles and structures can be achieved without changing physical embossing tools, thereby improving design flexibility while maintaining structured layer formation.

Inventive Principle:

Principle #35Parameter changes

2Shape

If material is removed from the structured layer for edge chamfering or rounding, then the edges are properly finished, but additional processing time is required

Engineering Contradiction:

Improveedge shapeVSAvoidprocessing time

Core Design Contradiction:

ShapeVSLoss of time

Solution Approach 1:

The patent applies preliminary action by creating the desired edge shape (chamfer or rounding) during the curing process itself through selective masking, rather than performing material removal in a subsequent processing step. The masking agent is applied in advance to define the final edge geometry, eliminating the need for separate edge finishing operations and reducing total processing time.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If a masking agent is applied in varying thicknesses to control curing, then flexible height profiles are created, but the process complexity increases

Engineering Contradiction:

Improveheight profile flexibilityVSAvoidprocess complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies local quality by varying the masking agent layer thickness at different locations on the layer. This creates locally different curing degrees, where areas with thicker masking have different height profiles compared to areas with thinner masking. This local variation in masking thickness enables flexible height profile creation while using a relatively simple overall process.

Inventive Principle:

Principle #3Local quality

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 method allows for the flexible creation of structured layers with varying height profiles, reducing the need for additional processing steps and enabling the production of workpieces with complex decorative patterns.

Implementation Method 1

The masking agent protects the layer or the material of the layer under the masking agent from curing completely during the curing process

Methodology Applied

Scientific EffectAbsorption (EM radiation): Absorption (EM radiation)

Implementation Method 2

curing the layer, wherein material of the layer at the first location below the masking agent applied thereto does not cure or cures less than material of the layer at the second location below the masking agent applied thereto

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS20250065364A1Method of producing a workpiece with a structured layer

Publication Date: 2025.02.27 HYMMEN GMBH MASCH UND ANLAGENBAU

AI summary

A method of manufacturing at least one workpiece having a structured layer on a support member (1) is disclosed. The method comprises the following steps:step (S10): Providing the support member (1) having a liquid and curable layer (2) on a support member surface (7);step (S12): applying a masking agent (3) onto the layer (2) such that the masking agent (3) has a first layer thickness at a first location (4) on the layer (2) and that the masking agent (3) has a second layer thickness at a second location (5) on the layer (2), wherein the first layer thickness is greater than the second layer thickness;step (S14): curing the layer (2), wherein material of the layer (2) at the first location (4) below the masking agent (3) applied at the first location does not cure or cures less than material of the layer (2) at the second location (5) below the masking agent (3) applied at the second location; andstep (S16): Removing uncured material of the layer (2) so that the cured material of the layer (2) forms the structured layer having a height profile on the support member (1).Furthermore, a device for carrying out the method is disclosed.