Crosslinked Polymer Coating for Plasticizer Migration in Mineral Panels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Extruded resilient floor or wall panels with high mineral filler to binder ratios face challenges such as low surface energy for adhesive compatibility, plasticizer migration leading to delamination, and warpage due to curable coatings, which affect the panel's adherence and durability.
Innovation Solution
A panel design featuring a core layer with a high mineral filler to binder ratio, supplemented by a crosslinked polymer coating on the bottom surface that prevents plasticizer migration and ensures strong adherence, comprising a crosslinked polymeric network with a high crosslink density to act as a barrier against plasticizer migration and maintain panel flatness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a high mineral filler to binder ratio is used to reduce costs and improve rigidity, then manufacturing cost decreases and rigidity increases, but adhesive compatibility deteriorates due to low surface energy
Solution Approach 1:
The patent applies a curable coating layer specifically to the bottom surface of the panel where adhesive contact occurs, while the core layer maintains its high mineral filler content for rigidity. This localized treatment provides high surface energy for adhesive compatibility only where needed, without compromising the overall cost-effectiveness and rigidity of the high-mineral core structure.
2Adaptability or versatility
If plasticizer is added to improve flexibility and processability of high mineral content panels, then flexibility increases and processing performance improves, but plasticizer migration occurs leading to delamination
Solution Approach 1:
The curable coating layer acts as an intermediary barrier between the plasticizer-containing core layer and the adhesive layer. This coating prevents direct contact between the migrating plasticizer and the adhesive, thereby maintaining adhesive integrity while allowing the core to retain its necessary flexibility through plasticizer addition.
Solution Approach 2:
The coating layer is applied in advance to the panel bottom surface before adhesive application, creating a protective barrier that preemptively prevents plasticizer migration to the adhesive interface. This preliminary protective action ensures long-term adhesive reliability without requiring changes to the flexible core formulation.
3Reliability
If a curable coating is applied to improve adhesive compatibility and prevent plasticizer migration, then adhesive integrity improves and plasticizer migration is prevented, but panel warpage occurs due to coating shrinkage
Solution Approach 1:
The patent carefully controls the formulation and curing parameters of the coating layer, including selecting coatings with lower shrinkage rates and optimizing cure conditions, to minimize the shrinkage-induced warpage while maintaining the essential functions of adhesive compatibility and plasticizer migration prevention.
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 crosslinked polymer coating effectively impedes plasticizer migration, maintaining adhesive integrity and preventing delamination, while ensuring the panel remains flat and adheres strongly to surfaces, enhancing the panel's durability and installation quality.
Implementation Method 1
at least one coating layer located on a bottom surface of the at least one core layer; wherein the at least one coating layer comprises an at least partly crosslinked polymer which is impermeable to the plasticizer
Implementation Method 2
the at least partially crosslinked polymer comprises a crosslinked polymeric network... the crosslinked polymeric network comprises a plurality of voids, and an average void diameter is smaller or equal to a diameter of gyration of the at least one plasticizer
Data Source
AI summary
The present invention relates to a panel, in particular a floor panel or wall panel, comprising a core layer comprising a mineral filler, a polymeric binder, and optionally a plasticizer; and a coating layer located on a bottom surface of the core layer. The invention further relates to a composition for forming a coating layer. The invention further relates to a method of manufacturing a panel, comprising providing a core layer comprising at least one mineral filler and at least one polymeric binder, applying a composition to at least part of a bottom surface of the core layer, and at least partially crosslinking the composition to obtain a coating layer.