Veneered Element Layer Structure for Bevel Appearance Control
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Solution Overview
Problem
Existing methods for producing veneered elements do not effectively control the overall design and appearance, particularly in managing defects such as cracks, knots, and holes in the veneer layer, and do not consider the impact of different layers on the final design.
Innovation Solution
A method involving the application of a first and second powder layer, followed by a veneer layer, and subsequent heating and pressing to form a veneered element with a bevel that exposes the layers, allowing for controlled design through layer combinations and features like moisture content, binders, and fillers, with optional substrate integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple layers with different properties are used to create design control, then the overall design and appearance of the veneered element is improved, but the device complexity and manufacturing process become more complex
Solution Approach 1:
The veneered element is divided into multiple functional layers: a first layer with first binder, a second layer with second binder having different properties, and a veneer layer. Each layer serves specific design functions, allowing independent control of appearance characteristics while managing complexity through clear functional segmentation.
Solution Approach 2:
The invention uses composite layer structures where layers with different binders and properties are combined. The first layer may have different mechanical properties while the second layer provides design features, creating a composite structure that achieves overall design control through material diversity.
2Strength
If layers are pressed together to merge them, then the strength and durability of the veneered element is improved, but the ability to control layer exposure and design appearance is reduced
Solution Approach 1:
The pressing process is optimized to achieve different degrees of layer merging in different regions. The bevel edges are designed to expose specific layers locally, while the center areas maintain full layer integration for strength. This local differentiation allows simultaneous achievement of bonding strength and design appearance control.
Solution Approach 2:
The invention introduces vertical dimensionality through bevel edges at different angles (e.g., 45 degrees). By creating stepped exposure levels, the design can control which layers are visible at different viewing angles and positions, adding a dimensional aspect to layer exposure control that complements the horizontal pressing integration.
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 creation of a strong and durable veneered element with a customizable appearance by exposing layers in the bevel, effectively managing defects and enhancing the overall design by controlling the visibility and interaction of layers.
Implementation Method 1
a first layer of a first powder, applying a second layer of a second powder above the first layer, applying a veneer layer above the second layer, heating and pressing the first layer, the second layer and the veneer layer together to form a veneered element
Implementation Method 2
heating and pressing the first layer, the second layer and the veneer layer together to form a veneered element
Implementation Method 3
heating and pressing the first layer, the second layer and the veneer layer together to form a veneered element
Data Source
AI summary
A method to produce a veneered element, including providing a first layer of a first powder and applying a second layer of a second powder above the first layer. Further the method includes applying a veneer layer above the second layer. Thereafter heating and pressing the first layer, the second layer and the veneer layer together to form the veneered element and forming a bevel at least partly along at least one side portion of the veneered element, where the first layer, the second layer and the veneer layer are at least partly exposed in the bevel.