Covered Panel Wear Layer for Transparency and Scratch Resistance
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Solution Overview
Problem
Existing floor panels with melamine or PVC surfaces suffer from issues such as transparency, scratch resistance, clicking sounds, and limited relief structure, while UV-cured acrylate resins face complexity and health risks, and electron beam curing requires complex logistics and equipment.
Innovation Solution
The use of thermally cured acrylate resin and unsaturated polyester resin as a wear layer, combined with thermoinitiators, allows for improved transparency, reduced residual tensile stresses, and controlled curing, enabling deep structures and reduced noise, with a softer and more scratch-resistant surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If melamine resin is used for the top layer, then wear resistance is improved, but transparency deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the wear layer by using acrylate resin instead of melamine resin, and by adjusting the ratio of monomer to oligomer (1:4 to 4:1), achieving both transparency and wear resistance simultaneously
Solution Approach 2:
The patent creates a composite wear layer system combining acrylate monomer and oligomer in specific ratios, forming a multi-component material system that achieves properties neither component could achieve alone - specifically combining transparency with enhanced wear resistance
2Strength
If melamine resin is used for the top layer, then scratch resistance is improved, but clicking sounds are generated
Solution Approach 1:
The patent converts the harmful clicking sound effect into a beneficial feature by using a softer acrylate-based wear layer that naturally dampens sounds, transforming the noise problem into a silent operation advantage while maintaining scratch resistance
Solution Approach 2:
The patent changes the mechanical parameters of the wear layer by selecting acrylate resin with specific hardness characteristics that provide sufficient scratch resistance while reducing acoustic emissions during panel movement
3Shape
If deep structures are formed in the melamine surface, then relief depth is improved, but white mountains occur
Solution Approach 1:
The patent changes the rheological parameters of the wear layer material by adjusting monomer and oligomer ratios, enabling the material to flow into deep relief structures uniformly without concentrating inclusions, achieving both deep relief and surface uniformity
4Reliability
If UV curing is used for the top layer, then surface properties are improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces the UV curing system with a thermal curing system, substituting the complex UV radiation infrastructure with simpler heated pressing equipment already present in laminate manufacturing lines, while maintaining superior surface properties
Solution Approach 2:
The patent changes the curing mechanism from photochemical (UV) to thermal, allowing the use of conventional heated presses instead of specialized UV curing equipment, thereby reducing manufacturing complexity while achieving excellent surface properties
5Reliability
If electron beam curing is used for the top layer, then surface properties are improved, but production complexity increases
Solution Approach 1:
The patent replaces the electron beam curing system with thermal curing, substituting the complex electron beam generation and control infrastructure with simple heated pressing equipment, dramatically reducing production complexity while maintaining surface quality
6Illumination intensity
If PVC is used for the top layer, then transparency is improved, but scratch resistance deteriorates
Solution Approach 1:
The patent creates a composite acrylate material system combining monomer and oligomer components that achieves both the transparency of PVC and superior scratch resistance, overcoming the limitations of pure PVC through material composition optimization
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 provides panels with enhanced transparency, reduced noise, improved scratch resistance, and better adhesion, allowing for deeper relief structures without the drawbacks of melamine or PVC, and avoids health risks associated with UV curing.
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.