Textured Panel Manufacturing via Phase-Change Material Removal
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Solution Overview
Problem
Existing methods for creating textured surfaces in panels require significant mechanical force to remove non-solid materials, leading to potential damage and wear of mechanical tools, and involve inefficient removal processes.
Innovation Solution
A method involving a phase transformation of the reaction product of the texturing substance and the curable substance into a gaseous or liquid phase, allowing for easy removal by suction or other non-contact means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical means are used to remove solid texturing substance from cured curable substance, then removal can be achieved, but mechanical power consumption increases and risk of damaging cured curable substance increases
Solution Approach 1:
The patent applies phase transition by transforming the texturing substance from solid phase to liquid phase through heating, enabling easy removal without mechanical force. The system heats the solid texturing substance (e.g., wax particles) to its melting point, converting it to liquid state that can be easily removed from the cured curable substance surface.
Solution Approach 2:
The patent changes the temperature parameter of the texturing substance to induce phase change. By controlling the heating temperature above the melting point of the texturing substance but below the degradation temperature of the cured curable substance, the method achieves selective softening and removal of the texturing material without mechanical contact.
2Ease of manufacture
If mechanical means are used to remove solid texturing substance from cured curable substance, then removal can be achieved, but mechanical means are subjected to wear and require continuous substitution and registration
Solution Approach 1:
The patent replaces the mechanical removal system with a thermal processing system. Instead of using mechanical brushes or scrapers that contact and wear against the cured curable substance, the invention uses controlled heating to melt and enable removal of the texturing substance, eliminating mechanical wear and associated maintenance issues.
3Shape
If texturing substance prevents portions of curable substance from curing, then textured surface can be formed, but removal of solid reaction product requires significant mechanical force
Solution Approach 1:
The patent uses phase transition of the texturing substance from solid to liquid through controlled heating. This allows the textured surface pattern to be maintained during curing while enabling easy removal of the texturing material afterward through melting, without requiring mechanical force that could damage the cured surface.
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 and damage-free removal of non-solid materials, reducing tool wear and enhancing manufacturing efficiency.
Implementation Method 1
said phase transformation involves transforming the reaction product of the texturing substance and the curable substance into a gaseous phase. For example, said phase transformation can comprise evaporation or sublimation.
Implementation Method 2
said phase transformation can comprise evaporation or sublimation
Implementation Method 3
polymerizing and/or solidifying the mixture consisting of resin A and liquid B
Data Source
Figure 1~2
AI summary
A method of manufacturing a panel (1) including a textured surface, comprising the successive steps of: supplying a substrate (2), applying a curable substance (3) onto the substrate (2), applying discrete quantities of a texturing substance (5, 11) onto the curable substance (3), curing at least a part of the curable substance (3), performing a phase transformation of at least one of the texturing substance (5) and a reaction product (13) of the texturing substance (11) and the curable substance (3), preferably into a fluid phase, to obtain a non-solid material removing non-solid material (3'', 5', 13') from the at least cured part of the curable substance, hence forming the panel (1) including the textured surface.