Thixotropic Coating for Deep 3D Structures on Wood Panels
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Solution Overview
Problem
Existing methods for creating structured surfaces on wood-based panels using liquid coatings, such as UV-curing or electron beam-curing systems, are limited to structure depths of 10-20 micrometers, which is insufficient for achieving deeper three-dimensional designs.
Innovation Solution
A method and device utilizing a two- or three-roller application process with a paint template where the rollers have a hard and soft surface, allowing for the transfer of paint into deeper engraved areas, enabling structure depths of 5-500 micrometers, preferably 10-50 micrometers, through UV radiation or solvent drying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional UV-curing or electron beam-curing systems are used to create structured surfaces on wood-based panels, then the surface can be cured and structured, but the structure depth is limited to 10-20 micrometers which is insufficient for achieving deeper three-dimensional designs
Solution Approach 1:
The patent applies parameter changes by modifying the viscosity characteristics of the coating material through thixotropic additives. The coating transitions from a high-viscosity state during application (preventing runs) to a lower-viscosity state during curing (allowing deep structure formation), enabling structure depths of 10-50 micrometers while maintaining design versatility
Solution Approach 2:
The patent uses composite materials by combining thixotropic additives with UV-curing or electron beam-curing paint systems. This composite coating material exhibits both thixotropic behavior for deep structure formation and radiation-curing properties for rapid solidification, achieving structure depths of 10-50 micrometers with detailed three-dimensional designs
2Manufacturing precision
If a liquid coating material is applied to create deep three-dimensional structures, then greater structure depth can be achieved, but the structure may run or deform before curing
Solution Approach 1:
The patent applies parameter changes by utilizing thixotropic additives that cause the coating material to exhibit shear-thinning behavior. The material maintains high viscosity at rest (preventing structure runs and deformation) but reduces viscosity under shear stress during application (enabling deep structure formation), achieving structure depths of 10-50 micrometers while maintaining structure integrity
Solution Approach 2:
The patent applies periodic action through the time-dependent viscosity change of the thixotropic coating. The material transitions from a stable high-viscosity state during application to a flowable lower-viscosity state during structure formation, then returns to high viscosity upon curing, enabling deep structures of 10-50 micrometers to be created without running or deforming
3Manufacturing precision
If indirect gravure printing is used to apply structure, then very fine structures in the range of 10 micrometers or less can be achieved, but the structure is a negative pore replica rather than a positive three-dimensional structure
Solution Approach 1:
The patent applies inversion by reversing the gravure printing approach. Instead of using engraved cells that hold paint (indirect gravure), the patent uses a roller with raised relief structures that directly transfer paint to create positive three-dimensional structures of 10-50 micrometers depth, converting the negative pore replica method into a positive structure formation method
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 production of three-dimensionally structured surfaces with significantly greater depth than previous methods, ensuring the structure remains intact until cured, allowing for varied and detailed designs like wood or stone imitations.
Implementation Method 1
the paint layer is then conveyed through a radiation source, in particular a UV radiation source, by means of the outlet roller
Implementation Method 2
The thixotropy of the paint is selected in such a way that an applied three-dimensional structure does not run until it has cured
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a method and device for coating a platelike workpiece (7) with a flowing medium with a three-dimensional and a structure depth of 5 - 500 micrometres, preferably 10 - 50 micrometres, wherein the application of the flowing medium is achieved with an engraved application roller (3) such that the application roller (3) both in the engraved recesses and the (non-engraved) projecting regions is coated with the flowing medium.