Veneered Element Defect Filling via Translucent Interlayer
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Solution Overview
Problem
Existing veneer production methods face challenges in effectively filling defects like holes and cracks in wood veneer layers without affecting the rest of the veneer, and in controlling the design and appearance of the veneer layer post-pressing.
Innovation Solution
A method involving a first layer and a second layer applied on a substrate, where the second layer is transparent or translucent, allowing the first layer to be visible through defects in the veneer layer, and preventing the first layer's material from permeating into the veneer layer, thereby filling defects and maintaining the veneer's original appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a wood veneer layer is applied directly to a core, then the production cost is reduced compared to solid wood flooring, but the veneer layer cannot be sanded and has limited design control after pressing
Solution Approach 1:
The solution segments the veneer structure into multiple layers: a base veneer layer applied to the core, and additional surface layers (such as colored layers or transparent layers) applied afterward. This allows the base layer to provide structural integrity and cost efficiency, while the surface layers enable design customization and sanding capability without increasing the fundamental cost structure.
Solution Approach 2:
The patent applies preliminary actions by preparing the base veneer layer with specific properties (such as pore structure, density, or surface characteristics) before applying subsequent layers. This preliminary preparation enables better adhesion, design control, and post-pressing versatility while maintaining the cost advantages of using a thin veneer base layer.
2Manufacturing precision
If material from the first layer permeates into the veneer layer during pressing, then defects may be filled, but the original appearance and design of the veneer is altered
Solution Approach 1:
The patent introduces a second layer as an intermediary between the first layer (which may contain filling material) and the veneer layer. This intermediary layer controls the permeation process by allowing selective passage of materials: it permits filling materials to reach defects in the veneer while blocking or filtering out materials that would alter the veneer's original appearance. The second layer thus mediates between the conflicting requirements of defect filling and appearance preservation.
Solution Approach 2:
The solution applies local quality by creating different permeability characteristics in different regions or at different stages of the pressing process. The second layer is designed to have localized properties that allow material passage only at defect locations (such as knots, holes, or cracks) while maintaining barrier properties in sound areas of the veneer, thereby filling defects selectively without altering the overall appearance.
3Reliability
If a transparent or translucent second layer is applied over the first layer, then the first layer remains visible through defects while preventing material permeation, but the structure complexity increases
Solution Approach 1:
The second layer is designed to perform multiple functions simultaneously: it acts as a barrier to prevent unwanted material permeation, serves as a visible medium through which the first layer remains observable in defect areas, and provides structural bonding between the first layer and the veneer. By consolidating these multiple functions into a single layer, the patent reduces the effective complexity compared to using separate dedicated components for each function.
Solution Approach 2:
The patent employs composite material principles by creating a multi-layer structure where each layer has specific properties that complement the others. The second layer is formulated as a composite with controlled transparency, adhesion characteristics, and permeability properties. This composite approach allows the layer to achieve multiple performance targets (visibility control, barrier function, structural integrity) without requiring equally complex separate components.
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 aesthetically appealing veneer layers with visible defects filled and the rest of the veneer remaining unaffected, enhancing the visual appeal and maintaining the veneer's original design and stability.
Implementation Method 1
the second layer prevents material from the first layer from permeating into the veneer layer
Data Source
AI summary
A method to produce a veneered element, the method including applying a first layer on a substrate, applying a second layer on the first layer, applying a veneer layer on the second layer, pressing the first layer, the second layer and the veneer layer together to form a veneered element, wherein, after pressing, the second layer is transparent or translucent such that the first layer is visible through a crack, cavity, hole and/or knot of the veneer layer. Also, such a veneered element.