Decorative Panel With Crosslinked Coating for Scratch Resistance
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Solution Overview
Problem
Resilient flooring materials suffer from poor scratch resistance due to the use of soft plasticized PVC wear layers and conventional UV coatings, which compromise surface integrity and aesthetics.
Innovation Solution
A decorative panel with a substrate and coating layer having a Shore D hardness of at least 80 and 85, respectively, eliminating the need for a separate wear layer, and utilizing a crosslinked coating layer with thermosetting resins and photo-initiators to enhance scratch resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a soft plasticized PVC wear layer is used, then the panel maintains flexibility and durability, but the scratch resistance deteriorates
Solution Approach 1:
The patent changes the hardness parameter of the wear layer from soft (conventional plasticized PVC) to rigid (Shore D hardness of at least 80), and the coating layer from conventional UV coating to a crosslinked coating with Shore D hardness of at least 85. This parameter change resolves the contradiction by achieving both durability and scratch resistance through increased hardness while maintaining flexibility through the crosslinked polymer structure.
Solution Approach 2:
The patent creates a composite structure combining a rigid wear layer (Shore D ≥ 80) with a crosslinked coating layer (Shore D ≥ 85) containing thermosetting resins. This composite material approach allows the wear layer to provide structural durability while the crosslinked coating provides enhanced scratch resistance, overcoming the limitations of soft plasticized PVC alone.
2Productivity
If a conventional UV coating is applied, then the production speed is fast and drying time is short, but the scratch resistance deteriorates
Solution Approach 1:
The patent changes the coating formulation from conventional UV-cured coatings to a crosslinked coating system with higher Shore D hardness (at least 85). The crosslinking process maintains the fast curing characteristics of UV coatings while significantly improving scratch resistance through the formation of a densely crosslinked polymer network that resists mechanical damage.
Solution Approach 2:
The patent applies a specialized crosslinked coating layer with distinct properties (Shore D ≥ 85) specifically on the wear layer surface where scratch resistance is most critical. This localized quality enhancement focuses the scratch-resistant properties exactly where needed without compromising the overall production efficiency.
3Reliability
If multiple layers (wear layer + UV coating) are used, then the protective function is improved, but the device complexity increases
Solution Approach 1:
The patent merges the wear layer and coating layer into an integrated protective system where the crosslinked coating layer is directly applied to and bonded with the rigid wear layer. This merging maintains the dual-function protection (durability from wear layer + scratch resistance from coating) while simplifying the overall structure by eliminating the need for separate soft wear layer and conventional UV coating combination.
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 panel achieves scratch resistance comparable to laminate flooring, with improved durability and reduced volatile organic compound emissions, maintaining aesthetic appeal and surface texture.
Implementation Method 1
The coating layer is a crosslinkable coating layer... comprising at least one crosslinkable prepolymer and at least one photo-initiator... curing said coating layer such that a crosslinked coating layer is obtained
Data Source
AI summary
The invention relates to a decorative panel, comprising at least one substrate comprising an upper surface and a bottom surface and two pairs of opposing side edges, wherein the substrate comprises at least one core layer and at least one decorative layer and the panel comprising at least one coating layer, wherein the coating layer is provided upon the upper surface of the substrate, wherein both the upper surface of the substrate and the upper coating surface of the coating layer have a predetermined Shore D hardness.