Veneered Element Pressure-Driven Permeation for Wear and Water Resistance
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Solution Overview
Problem
Existing veneer surfaces face challenges in wear resistance, water resistance, and production cost, particularly when using low-quality or thin veneers, and lack the aesthetic appeal of solid wood surfaces.
Innovation Solution
A method involving a substrate with a sub-layer applied to a veneer layer, where the sub-layer permeates through the veneer under pressure, and a protective thermoplastic layer is applied to enhance wear and water resistance, while the sub-layer's permeation alters the veneer's design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a thin wood veneer layer is used to reduce production cost, then production cost is reduced, but wear resistance and water resistance deteriorate
Solution Approach 1:
The invention uses a composite structure consisting of a thin veneer layer (0.2-1 mm) combined with a WFF (Wood Fibre Floor) surface layer. The WFF layer comprises wood fibres, binder, and wear-resistant particles (such as aluminium oxide) that provide enhanced wear and water resistance. This composite approach allows the use of thin, cost-effective veneer while achieving the durability properties of thicker, more expensive veneers through the protective WFF surface layer.
2Ease of manufacture
If a thin wood veneer layer is used to reduce production cost, then production cost is reduced, but water resistance deteriorates
Solution Approach 1:
The WFF surface layer acts as a protective barrier against water penetration. The mixture of wood fibres, binder, and wear-resistant particles creates a dense, water-resistant surface that protects the underlying thin veneer from moisture damage, enabling the use of cost-effective thin veneer while maintaining water resistance.
3Ease of manufacture
If low quality veneer is used to reduce production cost, then production cost is reduced, but aesthetic appeal deteriorates
Solution Approach 1:
The invention applies different quality requirements to different layers: the underlying veneer layer can be thinner and lower quality (serving as a cost-effective substrate), while the WFF surface layer provides the aesthetic appearance with its wood fibre composition and natural colour variations. This local differentiation of quality allows cost reduction in the veneer layer without compromising the visual appeal provided by the WFF surface.
4Reliability
If a protective thermoplastic layer is applied to enhance wear resistance, then wear resistance is improved, but device complexity increases
Solution Approach 1:
The WFF surface layer has a porous structure composed of wood fibres and binder that allows it to function as both a protective layer and an aesthetic surface. The porous nature provides pathways for the sub-layer to permeate through, creating decorative effects while maintaining protection. This eliminates the need for separate protective coatings, reducing device complexity while maintaining wear resistance.
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
The method improves wear and water resistance, reduces production costs, and enhances the aesthetic appeal by allowing the sub-layer to permeate through the veneer, creating a decorative effect similar to solid wood surfaces.
Implementation Method 1
applying pressure to the veneer layer and/or the substrate, such that at least a portion of the sub-layer permeates through the veneer layer
Implementation Method 2
applying a protective layer comprising a thermoplastic material on the veneer layer
Data Source
Figure 1A~1C
Figure 2~3
Figure 4~5
AI summary
The present disclosure relates to a method of producing a veneered element (10), comprising providing a substrate (1), applying a sub-layer (2) on a surface of the substrate (1), applying a veneer layer (3) on the sub-layer (2), and applying pressure to the veneer layer (3) and/or the substrate (1), such that at least a portion of the sub-layer (2) permeates through the veneer layer (3). The disclosure also relates to such a veneered element (10).