Digitally Printed Board Panels With Reinforced Mechanical Locking
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Solution Overview
Problem
Mechanical locking systems in directly printed floor panels tend to crack and fail under force, particularly at the insertion and locking grooves, leading to disengagement of panels.
Innovation Solution
A method involving extruding a substrate, laminating a thermoplastic film to the substrate, digitally printing a décor on the film, and applying a coating, which strengthens the substrate and enhances the mechanical locking system's durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mechanical locking system is provided in directly printed floor panels, then the panels can be joined together, but the locking system cracks and fails under force applied to the surface
Solution Approach 1:
A reinforcement layer is applied to the substrate before the printing step to strengthen areas that will later contain mechanical locking systems. This preliminary reinforcement prevents cracking when forces are applied to the panel surface during use.
Solution Approach 2:
The reinforcement layer is selectively applied only to specific portions of the substrate where mechanical locking systems will be installed, rather than uniformly across the entire panel. This provides localized strength where needed while maintaining the benefits of direct printing on the visible surface.
2Ease of operation
If substrate portions are removed to form mechanical locking systems, then panels can be joined, but the substrate thickness is reduced and strength is weakened
Solution Approach 1:
The reinforcement layer is applied to the substrate before portions are removed to create mechanical locking systems. This ensures that the remaining substrate portions maintain sufficient strength despite the reduction in thickness from material removal.
Solution Approach 2:
A composite structure is created by combining the substrate with a reinforcement layer made of different material properties. This composite construction allows the substrate to have portions removed for locking systems while the reinforcement layer compensates for the lost strength.
3Adaptability or versatility
If digital printing is used to print décor on the substrate surface, then design flexibility is improved and expensive gravure cylinders are eliminated, but the printed surface lacks protection and durability
Solution Approach 1:
The reinforcement layer is applied to the substrate before the printing step, creating a strengthened base that can support the printed décor. This sequence ensures both design flexibility from digital printing and durability from the underlying reinforcement structure.
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 bending strength and reduces brittleness, making the panels less prone to damage and enhancing the mechanical locking system's resilience.
Implementation Method 1
laminating a thermoplastic film to a first surface of the substrate after the substrate has passed the die
Implementation Method 2
The thermoplastic film can be laminated to the substrate at least partly by heat remaining in the substrate from the extrusion process
Data Source
AI summary
A method to produce a board element, including extruding a substrate including one or more substrate layers through a die, laminating a thermoplastic film to a first surface of the substrate after the substrate has passed the die, printing by a digital printing device a décor on a surface of the thermoplastic film when the thermoplastic film has been laminated to the substrate, and applying a coating directly on the printed thermoplastic film after printing. Also, a panel, such as a building panel, including a mechanical locking system.