Elastic Laminate Cover Layer With Cross-Linked Surface Coating
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Solution Overview
Problem
Conventional laminate floor coverings face issues with bubble formation, transparency problems, and adhesion to press plates when using separate decorative papers, and they often contain ecologically problematic compounds like PVC and plasticizers, leading to fogging and environmental concerns.
Innovation Solution
A method for producing elastic laminate cover layers involves impregnating a carrier fabric with a resin mixture, applying a cross-linkable surface coating, and cross-linking it, resulting in a transparent, chlorine-free, and non-fogging laminate that is chemically and abrasion-resistant, avoiding the use of PVC and plasticizers, and allowing for a simple and cost-effective production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a separate decorative paper is used in conventional laminate production, then design flexibility is improved, but bubble formation and adhesion problems occur
Solution Approach 1:
The patent merges the decorative paper layer with the overlay layer into a single integrated elastic laminate cover layer. This eliminates the interface between separate layers that causes bubble formation, while maintaining design flexibility through the ability to print decorative patterns directly onto the carrier fabric before impregnation.
Solution Approach 2:
The invention creates a composite material structure where the carrier fabric, resin mixture, and surface coating form an integrated elastic laminate. This composite approach combines the structural support of the fabric with the adhesive properties of the resin and the decorative functionality, eliminating adhesion problems between separate layers.
2Strength
If conventional laminate surfaces are made hard for durability, then abrasion resistance is improved, but impact noise and cracking increase
Solution Approach 1:
The patent changes the physical parameter of surface hardness to elasticity by using an elastic laminate cover layer instead of a hard melamine resin layer. This elastic surface maintains sufficient durability while absorbing impact energy, thereby reducing impact noise and preventing cracks that occur in hard laminates.
Solution Approach 2:
The invention employs a flexible elastic laminate cover layer that can deform under impact loads rather than remaining rigid. This flexibility allows the surface to absorb impact energy, reducing both the noise generated and the likelihood of cracking, while the cross-linked resin structure maintains abrasion resistance.
3Adaptability or versatility
If PVC and plasticizers are used to achieve flexibility, then elasticity is improved, but environmental harm and fogging occur
Solution Approach 1:
The patent replaces persistent harmful materials like PVC and plasticizers with environmentally benign alternatives. The elastic laminate uses water-based or solvent-based resins that provide the necessary flexibility without releasing harmful substances, creating a short-living alternative to persistent plastic pollutants.
Solution Approach 2:
The invention converts the harmful role of traditional plasticizers into a beneficial environmental feature. By eliminating substances that cause fogging and environmental harm, the elastic laminate provides flexibility through alternative mechanisms (elastic resin matrices) that actually benefit the environment by reducing pollution and improving indoor air quality.
4Adaptability or versatility
If elastic cover layers are produced by extruding film onto partially impregnated paper, then elasticity is improved, but process complexity increases
Solution Approach 1:
The patent merges the film extrusion step with the resin impregnation step into a single process. The carrier fabric is impregnated with a resin mixture that inherently provides elastic properties, eliminating the need for a separate film extrusion operation and simplifying the overall manufacturing process.
Solution Approach 2:
The resin mixture serves multiple functions simultaneously: it provides structural binding, imparts elastic properties, and forms the surface coating. This multi-functional resin system eliminates the need for separate materials and processing steps for each function, thereby reducing process complexity while maintaining elasticity.
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 provides a transparent, elastic, and abrasion-resistant laminate cover layer that prevents bubble formation and adhesion issues, is environmentally friendly, and offers improved acoustic and mechanical properties, including reduced impact noise and enhanced scratch resistance.
Implementation Method 1
b) one-sided application of a second resin mixture as a surface paint comprising a cross-linker and a pre-polymer that can be cross-linked via reactive end groups, c) cross-linking of the pre-polymer that can be cross-linked via reactive end groups
Data Source
AI summary
The invention relates to a method for producing a covering layer for elastic laminate comprising a) impregnating a carrier fabric, b) applying a surface coating comprising a crosslinker and a prepolymer that can be crosslinked via reactive end groups, c) crosslinking the crosslinkable prepolymer, and d) drying the elastic laminate covering layer. The papers obtainable in this manner are suitable for producing a laminate that, with the elastic outer face thereof, has a pleasant and appealing feel underfoot and good haptics.