Decorative Panel UV Coating With Texture Layer Gloss Control
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Solution Overview
Problem
Existing methods for producing decorative panels, particularly those with high gloss levels, are limited by surface roughness and unevenness, leading to visible creases and unsightly patterns due to the viscosity of UV coatings and the use of roller or curtain coating methods, which also pose environmental and cost issues.
Innovation Solution
A method involving the application of a texture layer with lower surface energy than the uncured coating, followed by UV curing, allows for controlled surface roughness and efficient removal of the texture layer, enabling high gloss levels without visible creases and reducing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If roller coating method is used to apply UV coating, then production speed and abrasion resistance are improved, but surface roughness increases and gloss level is limited to maximum 60%
Solution Approach 1:
A texture layer is introduced as an intermediary between the applicator roller and the UV coating. This texture layer with controlled surface roughness (Ra 0.01-0.5 μm) allows the roller to apply coating while preventing direct transfer of roller imperfections and coating viscosity-induced unevenness to the final surface, enabling gloss levels above 60% while maintaining high production speed
Solution Approach 2:
The surface roughness parameter of the applicator roller is changed from conventional values (Ra 0.5-3.5 μm) to a controlled range (Ra 0.01-0.5 μm) by using a texture layer. This parameter change enables the coating to achieve higher gloss levels (above 60%) while maintaining the efficiency of roller coating application
2Illumination intensity
If higher gloss level is achieved by conventional means, then surface reflectivity increases, but visible creases and unsightly patterns appear due to surface roughness
Solution Approach 1:
The texture layer acts as a mediator that decouples the coating application process from the final surface quality. It absorbs the unevenness caused by coating viscosity and roller imperfections, allowing high gloss levels (above 60%) to be achieved without visible creases or patterns, as the texture layer's controlled roughness (Ra 0.01-0.5 μm) prevents light scattering
Solution Approach 2:
The texture layer provides locally controlled surface properties with specific roughness (Ra 0.01-0.5 μm) that optimizes light reflection. This local quality control ensures uniform gloss distribution across the panel surface, preventing the appearance of creases and patterns while achieving high overall gloss levels
3Manufacturing precision
If curtain coating is used to reduce macro-undulations, then surface uniformity improves, but VOC emissions increase and production cost rises
Solution Approach 1:
The harmful excess coating material is extracted/eliminated by using a texture layer instead of applying large quantities of coating (100-200 g/m2) as in curtain coating. The texture layer allows uniform surface quality to be achieved with minimal coating material, dramatically reducing VOC emissions and production costs while maintaining surface uniformity
Solution Approach 2:
The texture layer serves as a disposable intermediary that enables precise surface control without requiring expensive curtain coating equipment or generating environmental harm. It achieves surface uniformity at low cost and with minimal environmental impact compared to conventional curtain coating methods
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 achieves decorative panels with predictable and repeatable surface roughness, allowing gloss levels up to 100%, while minimizing environmental impact and production costs by avoiding the need for inert environments and reducing VOC emissions.
Implementation Method 1
subjecting at least part of the texture layer to ultraviolet light such that at least part of the coating layer, in particular part of the coating layer which is covered by the texture layer, is cured, in particular via UV curing
Implementation Method 2
wherein the surface energy of the texture layer, in particular the texture layer applied at step c), is lower than the surface tension of the uncured coating layer, in particular the uncured coating layer formed at step b)
Data Source
AI summary
The invention relates to a decorative panel and to a method for producing a decorative panel, in particular a floor panel, wall panel or ceiling panel. The method comprises the steps of providing at least one decorative panel, the panel comprising a core layer comprising an upper surface and a bottom surface, applying at least one uncured coating onto the upper surface of the panel such that a coating layer is formed, creating a surface texture in the coating layer and curing the coating layer via UV curing.