Wood Panel Decorative Layer with Gas-Filled Microspheres
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Solution Overview
Problem
The existing methods for producing three-dimensional surface structures on wood-based panels require complex and costly processes involving structured press plates, which are specific to each desired surface structure, making it impractical and expensive to introduce synchronous surface structures.
Innovation Solution
A method that uses gas-filled microspheres in the decorative layers, applied through a combination of gravure and digital printing, to create optical three-dimensional synchronous surface structures without the need for structured press plates, achieving the desired surface effects through differences in gloss levels and allowing for various decorative effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If structured press plates are used to produce three-dimensional synchronous surface structures, then the desired surface structure can be achieved, but the device complexity and production costs increase significantly
Solution Approach 1:
The invention extracts the surface structuring function from the press plate and transfers it to the decorative layer material itself. Gas-filled microspheres are incorporated into the decorative layer, which expand during pressing to create the three-dimensional surface structure. This eliminates the need for complex structured press plates while achieving the desired synchronous surface structures.
Solution Approach 2:
The mechanical structuring system (structured press plates) is replaced with a chemical-physical system (gas-filled microspheres that expand under heat and pressure). The microspheres undergo expansion during the pressing process, creating the three-dimensional surface structure through material transformation rather than mechanical imprinting.
2Manufacturing precision
If different structured press plates are produced for every desired surface structure, then synchronous surface structures can be achieved, but the production time increases due to press plate replacement interruptions
Solution Approach 1:
The decorative layer with gas-filled microspheres serves multiple functions: it provides the decorative pattern, contains the structuring agent (microspheres), and creates the three-dimensional surface structure through expansion. A single unstructured press plate can produce different synchronous surface structures by varying the decorative layer composition, eliminating the need for multiple specialized press plates and allowing production continuity.
Solution Approach 2:
The structuring capability is prepared in advance by incorporating gas-filled microspheres into the decorative layer material before printing and pressing. The microspheres are pre-positioned in the decorative layer, so when pressing occurs, the structure forms automatically through expansion without requiring pre-structured press plates or interruptions for plate changes.
3Manufacturing precision
If structured press plates are manufactured for each surface structure, then the desired three-dimensional structures can be produced, but the production costs increase due to multiple press plate manufacturing and replacement
Solution Approach 1:
The invention replaces expensive, durable structured press plates with a consumable component (gas-filled microspheres in the decorative layer) that is applied fresh for each production run. The microspheres are incorporated into the decorative layer material, which is applied in each pressing cycle, eliminating the need for costly press plate manufacturing and replacement while maintaining high production precision.
4Device complexity
If optical three-dimensional structures are created without structured press plates, then production costs and complexity are reduced, but the ability to achieve synchronous surface structures is compromised
Solution Approach 1:
The gas-filled microspheres are selectively distributed within the decorative layer according to the desired surface structure pattern. The decorative layer is printed with specific patterns, and the microspheres are incorporated into the printed areas, creating local three-dimensional structures that synchronize with the decor pattern. This allows different regions to have different surface structures as needed.
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 production of optically three-dimensional synchronous surface structures without the need for structured press plates, allowing for multiple three-dimensional structures to be achieved with the same press plate, defined during the printing process, and reduces production costs by eliminating the requirement for specific press plates.
Implementation Method 1
pressing of the layer structure in a short-cycle press at temperatures between 150 and 250° C. and a pressure between 100 and 1000 N/cm 2, with the gas-filled microspheres expanding
Data Source
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AI summary
The present invention relates to a method for producing a material panel provided with a decorative layer. A material panel made of a wood-based material or a wood-based material-plastic composite, with a top and a bottom surface, is provided. Then, at least one resin layer and at least one primer layer are applied to the top surface; at least one decorative layer is applied to the top surface by direct printing, wherein the at least one decorative layer comprises at least one additive in the form of gas-filled microspheres; at least one protective layer is applied to the at least one decorative layer; and the at least one protective layer is allowed to partially dry.At least one wear-resistant layer is then applied to the protective layer, whereby the wear-resistant layer is applied in the following steps: application of a first resin layer; uniform sprinkling of abrasion-resistant particles onto the first resin layer; drying of the first resin layer; application of at least one further resin layer; and drying of the further resin layer. The layered structure is then pressed in a short-cycle press at temperatures between 150 and 250°C and a pressure between 100 and 1000 N/cm², whereby the gas-filled microspheres expand.