UV-Cured Decorative Panel Manufacturing via Material Jetting
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Solution Overview
Problem
Existing methods for manufacturing decorative panels with a laminated structure require high investments in machinery and energy, often resulting in obsolete stock and waste.
Innovation Solution
The method involves using additive manufacturing techniques, specifically material jetting, to apply a top decorative layer directly onto a panel substrate material, allowing for the creation of a structured surface and optimizing raw material chemistry and application techniques for maximum efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional DPL technique is used for manufacturing laminate panels, then the top layer is formed by consolidating decor paper and synthetic material with hardening and cross-linking, but high investments in machinery, tooling and inventory are required
Solution Approach 1:
The patent replaces the traditional mechanical hot-pressing system with a UV-curing system. Instead of using heat and pressure to consolidate and cross-link the synthetic material, the invention uses UV radiation to trigger photopolymerization, thereby forming the laminate layer. This substitution eliminates the need for complex hot-pressing machinery, tooling, and high energy consumption, while still achieving reliable laminate layer formation through chemical curing.
Solution Approach 2:
The patent changes the curing mechanism from thermal (heat-based) to photchemical (UV-based). By altering the energy input parameter from thermal energy to UV radiation, the process achieves faster curing times, lower energy consumption, and eliminates the need for high-temperature pressing equipment. This parameter change enables simpler machinery while maintaining the reliability of laminate layer formation.
2Reliability
If traditional hot-pressing method is used, then laminate layer is formed through consolidating and cross-linking synthetic material, but a large amount of energy is consumed
Solution Approach 1:
The patent changes the energy input parameter from thermal energy (high temperature hot-pressing) to photchemical energy (UV radiation). This parameter change enables the curing process to occur at lower temperatures with significantly reduced energy consumption, while still achieving reliable laminate layer consolidation through photopolymerization triggered by UV light.
Solution Approach 2:
The patent substitutes the thermal-mechanical hot-pressing system with a photchemical curing system. Instead of using heat and pressure to consolidate the laminate layer, UV radiation triggers chemical cross-linking, thereby reducing energy consumption while maintaining consolidation reliability.
3Shape
If traditional press treatment is used to form relief and attach laminate layer, then structured surface is created, but high investments in tooling are required
Solution Approach 1:
The patent replaces the mechanical press treatment with a photopolymerization-based system. Instead of using a structured press element to mechanically form relief and attach the laminate layer, the invention uses UV-curing to chemically bond the layers while allowing the relief structure to be formed through digital printing patterns or mold inserts that require minimal tooling investment. This substitution reduces tooling requirements while maintaining relief formation capability.
4Productivity
If traditional DPL technique is used for mass production, then laminate panels are manufactured, but obsolete stock and waste are generated
Solution Approach 1:
The patent segments the laminate panel manufacturing into separate functional layers: a substrate layer and a decorative laminate layer. The decorative layer is applied only where needed using UV-curing technology, allowing for precise control over material application. This segmentation enables on-demand production and reduces obsolete stock by allowing customization without requiring entire batches to be produced and stored, thereby reducing waste.
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 enables a more fluent and economical mass production of decorative panels, reducing waste and obsolete stock, while achieving desired functional and visual properties such as sound dampening, abrasion resistance, and realistic decoration imitations.
Implementation Method 1
applying said top decorative layer to said panel substrate material at least through one or more additive manufacturing technique, more particularly at least through material jetting
Data Source
AI summary
Method for manufacturing decorative panels, where the panel includes a panel substrate material and a top decorative layer. The method includes applying the top decorative layer to the panel substrate material at least through additive manufacturing techniques, more particularly through material jetting. The process further concerns panels obtained or obtainable through such method.