Floor Covering Wear Layer Gloss Control via Segmented Lacquer
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Solution Overview
Problem
Existing methods for manufacturing floor coverings with thermoplastic synthetic materials fail to achieve desired sharpness and gloss differences in surface structures, resulting in an artificially looking appearance.
Innovation Solution
The method involves applying two lacquer layers with different gloss degrees using UV and Excimer radiation techniques, where one lacquer layer is hardened with UV radiation and the other with Excimer radiation, allowing for targeted hardening and achieving a matte or glossy finish on the surface and in recesses respectively, while maintaining the thermoplastic nature of the wear layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single lacquer layer is applied to the floor covering surface, then the manufacturing process is simple, but the gloss degree difference between surface and recesses is insufficient resulting in artificial appearance
Solution Approach 1:
The lacquer coating is segmented into two distinct layers: a first lacquer layer applied to recesses and a second lacquer layer applied to the surface between recesses. This segmentation allows each layer to have different gloss properties, with the first layer providing a matte finish in recesses and the second layer providing a glossy finish on the surface, thereby achieving the desired gloss degree difference and natural appearance.
Solution Approach 2:
Different lacquer layers are applied to different locations of the floor covering surface. The first lacquer layer is locally applied to recesses to create a matte appearance, while the second lacquer layer is locally applied to the surface between recesses to create a glossy appearance. This local quality differentiation resolves the contradiction by providing location-specific gloss properties.
2Productivity
If UV radiation is used to harden the lacquer layer, then the hardening process is fast and efficient, but the lacquer layer cannot achieve the desired matte finish in recesses
Solution Approach 1:
The hardening process is segmented into two distinct radiation steps: UV radiation for the first lacquer layer in recesses and Excimer radiation for the second lacquer layer on the surface. This segmentation allows each radiation type to be optimized for its specific function, maintaining fast hardening speeds while achieving the desired gloss degree control for each location.
Solution Approach 2:
Different radiation parameters are applied to different lacquer layers. UV radiation with specific wavelength and intensity parameters is used for the first lacquer layer to achieve matte finish in recesses, while Excimer radiation with different parameters is used for the second lacquer layer to achieve glossy finish on the surface. This parameter change resolves the contradiction by allowing fast hardening while controlling gloss degree.
3Manufacturing precision
If Excimer radiation is used to harden the lacquer layer, then the matte finish is achieved, but the hardening process is slower and less efficient
Solution Approach 1:
The hardening process is divided into two segments with different radiation types. UV radiation is used for the first lacquer layer where fast hardening is needed, while Excimer radiation is used for the second lacquer layer where matte finish precision is prioritized. This segmentation allows the system to achieve both fast hardening and precise gloss control without sacrificing overall productivity.
4Ease of manufacture
If chemical foaming technique is used to create surface relief, then the process is simple, but the relief lacks sharpness and precision
Solution Approach 1:
The chemical foaming technique is replaced with a mechanical structuring process where a structured roller or press element is used to create the relief pattern on the wear layer. This mechanical approach provides precise control over the relief geometry, achieving the desired sharpness and precision while maintaining ease of manufacture through a straightforward mechanical process.
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
This approach allows for a significant difference in gloss degrees between surface and recesses, enhancing the visual appearance and physical properties of the floor covering, such as wear resistance, by selectively hardening lacquer layers with specific radiation techniques.
Implementation Method 1
applying a first lacquer layer and hardening the first lacquer layer by means of UV radiation
Implementation Method 2
applying a second lacquer layer and hardening the second lacquer layer by means of Excimer radiation
Data Source
Figure 1~3
Figure 4
AI summary
Floor covering with at least a substrate layer (9A), a decor layer (7) and a transparent wear layer (6), wherein a relief is realized in said wear layer (6), wherein this relief comprises recesses (24), characterized in that said transparent wear layer (6) comprises at least two lacquer layers (25-26), namely a first lacquer layer (25) located at least on the bottom of at least one of said recesses (24), and a second lacquer layer which is interrupted at the location of the recess (24) concerned. The invention further also comprises a method for manufacturing such floor covering.