Decorative Panel Texture Layer for Uniform High-Gloss UV Finishes
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Solution Overview
Problem
Existing methods for producing decorative panels with high gloss levels are limited by surface roughness, leading to visible creases and unevenness, and traditional curtain coating methods are costly and environmentally harmful.
Innovation Solution
A method involving the application of a texture layer with lower surface energy than the coating layer, followed by UV curing, allows for precise control of surface roughness and gloss level, enabling high gloss finishes without visible imperfections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If roller-coating method is used to apply UV coating, then production speed and efficiency are improved, but surface gloss level is limited to maximum 60% due to visible creases and unevenness
Solution Approach 1:
A texture layer is applied to the coating surface before UV curing to pre-establish the desired surface profile. This preliminary action allows the coating to achieve high gloss levels without the creases and unevenness that normally limit roller-coating applications to maximum 60% gloss.
Solution Approach 2:
The texture layer acts as an intermediary between the roller applicator and the final coating surface. It mediates the transfer of coating material while controlling surface morphology, enabling high gloss finishes without the direct contact limitations of roller-coating.
2Manufacturing precision
If curtain coating method is used to reduce macro-undulations, then surface smoothness is improved, but production cost increases and environmental impact worsens due to large quantities of VOCs released
Solution Approach 1:
The harmful VOC emissions and high material consumption associated with curtain coating are extracted and replaced by the texture layer method. The texture layer achieves equivalent or superior surface smoothness without requiring large quantities of coating material or releasing harmful VOCs into the environment.
Solution Approach 2:
The invention changes the approach from adding large quantities of coating material (curtain coating) to controlling surface morphology through a texture layer. This parameter change reduces VOC emissions and material consumption while maintaining surface smoothness.
3Quantity of substance
If coating is applied evenly over textured panel surface, then coverage is improved, but unsightly wavy patterns and macro-undulations are created on the top surface
Solution Approach 1:
The texture layer is applied in advance to the coating surface to pre-establish the desired uniform surface profile. This preliminary action prevents the wavy patterns and macro-undulations that occur when coating is applied directly over textured panels, even with adequate coverage.
4Illumination intensity
If high gloss level is achieved through traditional methods, then surface reflectivity is improved, but visible creases and unevenness scatter light and reduce reflection
Solution Approach 1:
The texture layer is applied before UV curing to pre-establish a uniform surface profile that enables high reflectivity without light-scattering creases. This preliminary action resolves the contradiction between achieving high gloss and maintaining surface uniformity.
Solution Approach 2:
The texture layer acts as an intermediary that enables high surface reflectivity by controlling the coating surface morphology, preventing the formation of light-scattering creases and unevenness that normally limit gloss levels.
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 controlled surface roughness, allowing for gloss levels up to 100% while reducing production costs and environmental impact by avoiding nitrogen inerting and minimizing VOC emissions.
Implementation Method 1
subjecting at least part of the coating layer, in particular part of the coating layer which is covered by 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 the texture layer applied at step c), is lower than the surface tension of the uncured coating layer
Data Source
Figure 1a~1d
Figure 1e~2
AI summary
The invention relates to a decorative panel (100) 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 (100), the panel comprising a core layer (101) comprising an upper surface (101a) and a bottom surface (101b), applying at least one uncured coating (104) onto the upper surface (101a) of the panel such that a coating layer (104) is formed, creating a surface texture (104a) in the coating layer (104) and curing the coating layer via UV curing.