Floor Covering Print Pattern Direct Substrate Application

Solution Overview

Problem

The complexity of the production process for coverings such as floor and wall coverings, which require multiple sequential layers and curing steps, limits flexibility and increases production costs, making it difficult to produce a variety of designs efficiently.

Innovation Solution

A covering with a print pattern directly applied to a substrate, using digital printing techniques like inkjet or laser printing, which simplifies the production process and allows for flexible design adaptation by applying a wear layer and additional layers in a single step, reducing the need for pre-coatings and sequential curing steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple sequential layers and curing steps are used to produce coverings, then the structural integrity and design quality are improved, but the production process complexity and production costs increase

Engineering Contradiction:

Improvedesign qualityVSAvoidproduction process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines multiple separate layers (substrate, print layer, wear layer) into a single integrated layer where the print pattern is directly applied to the substrate and the wear layer is formed simultaneously or in a simplified sequential manner. This merging eliminates the need for multiple sequential curing steps while maintaining the structural integrity and design quality of the covering.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The substrate serves multiple functions: it provides structural support, acts as a base for the print pattern, and integrates with the wear layer to form a complete surface layer. This multi-functionality reduces the number of separate components and processing steps required, thereby simplifying the production process while maintaining design quality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If multiple sequential layers and curing steps are used to produce coverings, then the structural integrity and design quality are improved, but the production costs increase

Engineering Contradiction:

Improvedesign qualityVSAvoidproduction costs

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent combines multiple separate layers (substrate, print layer, wear layer) into a single integrated layer where the print pattern is directly applied to the substrate and the wear layer is formed simultaneously or in a simplified sequential manner. This merging eliminates the need for multiple sequential curing steps while maintaining the structural integrity and design quality of the covering.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts and eliminates unnecessary intermediate layers and curing steps from the traditional multi-layer production process. By directly applying the print pattern to the substrate and forming the wear layer in a simplified manner, the process removes redundant operations, thereby reducing production costs while maintaining design quality.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If traditional multi-layer production process is used, then durable coverings are produced, but the flexibility to produce various designs is reduced

Engineering Contradiction:

Improvecovering durabilityVSAvoiddesign flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent combines multiple separate layers (substrate, print layer, wear layer) into a single integrated layer where the print pattern is directly applied to the substrate and the wear layer is formed simultaneously or in a simplified sequential manner. This merging eliminates the need for multiple sequential curing steps while maintaining the structural integrity and design quality of the covering.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent enables dynamic design flexibility by allowing the print pattern to be directly applied to the substrate in various configurations and designs. The integrated layer structure accommodates different print patterns, colors, and designs without requiring changes to the fundamental production process, thereby providing adaptability while maintaining durability.

Inventive Principle:

Principle #15Dynamics

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 simplifies the production process, enhances flexibility in design options, and reduces production costs by eliminating the need for multiple layers and curing steps, enabling more efficient and cost-effective production of various covering types.

Implementation Method 1

using digital printing techniques like inkjet or laser printing

Methodology Applied

Scientific EffectDigital printing (inkjet or laser):

Implementation Method 2

applying a wear layer and additional layers in a single step

Methodology Applied

Scientific EffectLayer application: Deposition (physical)

Data Source

PatentEP4056367A1Covering and method for producing coverings

Publication Date: 2022.09.14 I4F LICENSING NV

AI summary

The current invention concerns coverings such as a floor covering, wall covering or ceiling covering, said covering comprising at least one substrate and at least one surface layer, said surface layer comprising a print pattern and a wear layer, whereby said print pattern is directly applied to said substrate, and further concerns a method to produce such coverings.