Abrasion-Resistant Floor Panel Production via Calendering
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Solution Overview
Problem
Existing methods for producing abrasion-resistant and waterproof SPC floor coverings result in products with poor transparency and higher costs due to the need for thick wear layers, which are costly and affect the color impression and appearance.
Innovation Solution
A method involving the application of abrasion-resistant particles directly onto a decorative layer with a polyurethane primer, followed by a thin covering layer, eliminating the need for a separate intermediate layer with embedded particles, and using a calendering process to adhere the layers without gluing, allowing for thinner wear layers and improved transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick wear layer is used to ensure abrasion resistance, then wear resistance is improved, but transparency and color perception deteriorate
Solution Approach 1:
The patent applies abrasion-resistant particles only in the wear layer (top layer) rather than throughout the entire panel thickness. This localized application provides abrasion resistance where needed while maintaining transparency in the bulk material, resolving the contradiction between wear resistance and transparency.
Solution Approach 2:
The patent creates a composite wear layer combining PVC binder with abrasion-resistant particles (alumina, silica, or corundum). This composite structure provides the necessary durability and scratch resistance while using minimal material thickness, thus maintaining the transparency of the overall panel.
2Reliability
If a thick wear layer is used to ensure abrasion resistance, then wear resistance is improved, but production costs increase
Solution Approach 1:
By concentrating abrasion-resistant particles only in the thin wear layer rather than distributing them throughout the entire panel, the patent reduces material usage and production costs while maintaining the required wear resistance performance.
Solution Approach 2:
The patent changes the distribution parameter of abrasion-resistant particles from uniform throughout the panel to concentrated in the wear layer only. This parameter change reduces the total amount of expensive abrasive material needed while maintaining effective wear resistance.
3Reliability
If a separate intermediate layer with embedded particles is produced, then abrasion resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the wear layer formation with the main panel extrusion process. The abrasion-resistant particles are fed into the extruder along with the PVC compound, and the wear layer is formed integrally with the panel body in a single continuous process, eliminating the need for separate intermediate layer production and assembly steps.
Solution Approach 2:
The abrasion-resistant particles are pre-mixed with the PVC compound in the extruder before extrusion. This preliminary mixing ensures uniform distribution of particles in the wear layer during the extrusion process itself, eliminating the need for subsequent particle embedding or separate layer assembly operations.
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 produces abrasion-resistant and waterproof panels with high wear resistance in a cost-effective manner, maintaining product quality and improving transparency, while reducing material usage and production complexity.
Implementation Method 1
The layers are adhered to one another in a calendering process without the use of gluing
Implementation Method 2
applying at least one polyurethane primer layer to the at least one decorative layer
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a method for producing an abrasion- and water-resistant multi-layer panel, in particular an abrasion- and water-resistant floor panel, comprising the steps of: providing at least one plastic carrier board, in particular a PVC carrier board; applying at least one decorative layer to the at least one plastic carrier board; uniformly sprinkling abrasion-resistant particles onto the at least one decorative layer; applying at least one cover layer.