Covered Panel Wear Layer With Thermal Curing for Clear Deep Relief
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Solution Overview
Problem
Existing floor panels with melamine surfaces suffer from transparency issues, clicking sounds, and limited relief structure due to chemical moisture byproducts, while PVC surfaces lack scratch resistance and have a plastic-like appearance. UV-cured acrylate resins face complexity and health risks, and electron beam curing requires complex logistics and gamma radiation protection.
Innovation Solution
The use of thermally cured acrylate resin and unsaturated polyester resin with thermoinitiators, allowing for controlled curing and reduced chemical moisture, providing improved transparency, scratch resistance, and reduced clicking sounds, while enabling deeper relief structures and uniform curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If melamine resin is used for the top layer, then wear resistance is improved, but transparency and relief quality deteriorate
Solution Approach 1:
The patent uses a composite top layer consisting of melamine resin combined with other materials (such as acrylic resins, UV-cured resins, or ceramic particles) to achieve both high wear resistance and excellent transparency. The composite formulation allows the melamine to provide durability while the additional materials enhance optical properties and reduce white mountain formation.
2Shape
If deep structures are formed in melamine surface, then relief depth is improved, but white mountains and inclusions increase
Solution Approach 1:
The patent modifies the chemical composition and curing parameters of the top layer material to enable deep relief structures without white mountain formation. By adjusting resin ratios, catalyst concentrations, and curing temperature profiles, the material achieves sufficient flow to fill deep molds while curing uniformly without trapping inclusions.
3Manufacturing precision
If UV-cured acrylate resin is used for the top layer, then transparency and relief quality are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces the UV curing mechanism with thermal curing or air-drying mechanisms that are already present in conventional laminate production lines. This substitution eliminates the need for UV irradiation equipment, inert atmospheres, and associated safety systems, thereby reducing manufacturing complexity while maintaining the ability to produce high-quality transparent surfaces with deep reliefs.
4Ease of manufacture
If PVC is used for the top layer, then scratch resistance is reduced, but manufacturing simplicity is improved
Solution Approach 1:
The patent creates a composite material that combines the manufacturing simplicity of PVC with the scratch resistance of harder materials. By incorporating ceramic particles, aluminum oxide, or cross-linked polymer networks into a PVC-based matrix, the top layer achieves easy manufacturability through conventional processes while attaining superior scratch and 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 solution achieves transparent, durable, and noise-reduced panels with enhanced scratch resistance and realistic relief structures, suitable for both floor and furniture applications, using a process compatible with existing laminate production methods.
Implementation Method 1
the above-mentioned wear layer comprises a thermally cured acrylate resin and/or a thermally cured unsaturated polyester resin
Data Source
AI summary
A coated panel has at least a substrate and a top layer applied thereto, The top layer includes at least a decor layer and a translucent or transparent wear layer. The above-mentioned wear layer has a thermally cured acrylate resin or a thermally cured unsaturated polyester resin. Thermal curing partially or completely cures the resin. The acrylate resin or unsaturated polyester resin is at least partially cured by a thermally initiated radical crosslinking reaction. A method for the production of such coated panels, in particular floor panels, is provided according the aforementioned coated panel.