Veneer Element Defect Coloring via Colored Sub-Layer
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Solution Overview
Problem
Veneer elements with defects such as cracks, holes, or knots are often considered low quality and discarded due to aesthetic concerns when glued directly onto substrates, as the glue fills these defects and can create visible, unappealing white spots that do not match the veneer color.
Innovation Solution
A method involving a substrate with a sub-layer containing colored filler particles is applied, where the sub-layer is pressed with a veneer layer to form a veneer element, allowing the sub-layer to be visible through defects while keeping the dense portions uncolored, using particles larger than conventional pigments to prevent permeation and maintain the veneer's original appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If veneer layers are glued directly onto the substrate, then the manufacturing process is simple, but the defects in the veneer are filled with glue creating visible white spots that reduce aesthetic appeal
Solution Approach 1:
A sub-layer comprising colored filler particles and binder is introduced between the substrate and the veneer layer. This intermediary sub-layer fills the defects in the veneer and provides color matching, preventing the formation of visible white spots while maintaining manufacturing simplicity.
Solution Approach 2:
The sub-layer is applied selectively to address local defects in the veneer. The colored filler particles are concentrated in regions where defects occur, providing localized color correction without affecting the entire veneer surface uniformly.
2Illumination intensity
If dark colouring substances or pigments are used in the sub-layer, then defects can be colored to improve appearance, but the pigments become visible in the dense portions of the veneer layer after pressing
Solution Approach 1:
The sub-layer is designed with porous characteristics that allow it to be absorbed into the veneer defects during pressing. The porous structure enables the colored filler particles to penetrate into cracks and holes without excessive migration into dense veneer portions, achieving localized coloration.
Solution Approach 2:
The particle size of the colored filler is optimized to a specific range that prevents permeation into dense veneer portions while still effectively filling defects. This parameter control ensures that the coloring effect is confined to defect areas without affecting the overall veneer appearance.
3Illumination intensity
If conventional pigments are used to color the sub-layer, then defects can be filled with color, but the pigments permeate through dense portions of the veneer layer causing unwanted coloration
Solution Approach 1:
The particle size of the colored filler is changed from conventional fine pigments to a larger size range (0.1-300 μm). This parameter change prevents the filler particles from permeating through the dense portions of the veneer layer, thereby avoiding unwanted coloration while still effectively filling and coloring defects.
4Illumination intensity
If veneers with defects are discarded, then high aesthetic quality is maintained, but material waste increases and production cost rises
Solution Approach 1:
Veneers with defects that would normally be discarded are reused by applying the colored sub-layer. The defects are transformed from harmful aesthetic flaws into beneficial features where the colored filler provides natural-looking color matching, converting waste material into valuable product.
Solution Approach 2:
The colored filler particles in the sub-layer provide color matching that simulates natural wood grain patterns. This coloration technique allows defective veneers to achieve an aesthetically pleasing appearance that resembles solid wood, enabling their reuse in applications previously reserved for high-quality veneers.
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 enhances the aesthetic appeal by coloring defects while keeping solid portions uncolored, improving the visual impression and reducing waste by utilizing low-quality or thin veneers, achieving a solid wood-like appearance and increased wear resistance.
Implementation Method 1
applying pressure, preferably heat and pressure, to the veneer layer and/or the substrate
Implementation Method 2
applying pressure, preferably heat and pressure, to the veneer layer and/or the substrate
Implementation Method 3
providing a sub-layer, comprising a binder and colored filler particles
Data Source
AI summary
A method to produce a veneer element, including defects and dense portions. The method includes providing a substrate, providing a sub-layer, including a binder and colored filler particles, applying the sub-layer on a first surface of the substrate, applying a veneer layer on the sub-layer, and applying pressure, preferably heat and pressure, to the veneer layer and/or the substrate, thereby forming a veneer element wherein, after pressing, the sub-layer is visible through a defect of the veneer element such as crack, cavity, hole and/or knot of the veneer layer. Also, a veneer element.