Floor Panel Cork Primer High-Solid Coating
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Solution Overview
Problem
Cork floor panels often exhibit defects in the decorative layer due to indentations in the cork surface, which are not adequately filled by conventional coating systems, leading to visual and application issues.
Innovation Solution
The use of high-solid coating systems with a volatile component fraction of no more than 10% by volume, which fill indentations in the cork surface and reduce layer thickness variation during curing, combined with UV-curing and specific application methods to ensure a uniform primer layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional coating systems with high volatile solvent fraction (40-65% by volume) are used to fill indentations in the cork surface, then the indentations are initially filled, but during drying the layer thickness reduces significantly more in the indentation regions, resulting in deep dents remaining in the primer surface
Solution Approach 1:
The patent changes the key parameter of volatile solvent fraction from 40-65% by volume in conventional systems to a maximum of 10% by volume in the new coating system. This parameter change reduces the differential evaporation rate between indentation regions and flat areas, preventing deep dent formation while maintaining the ability to fill surface indentations uniformly.
Solution Approach 2:
The patent introduces a dynamic control mechanism by using a coating system whose composition is specifically designed to control the drying process. The reduced volatile fraction creates a more controlled evaporation dynamic that prevents excessive material withdrawal from indentation regions during curing, thereby maintaining surface uniformity.
2Manufacturing precision
If conventional coating systems are applied to cork surfaces with indentations, then the coating fills the indentations, but the printing device loses contact with the primer in the dent regions, resulting in inadequate decorative layer application
Solution Approach 1:
By changing the volatile solvent fraction parameter to a maximum of 10% by volume, the coating system maintains a more consistent layer thickness during drying. This prevents the formation of deep dents that would cause the printing device to lose contact, thereby ensuring reliable decorative layer application across the entire surface including former indentation regions.
3Manufacturing precision
If conventional coating systems with substantial volatile solvent fraction are used, then the coating system can be applied to fill indentations, but the layer thickness reduces by 40-65% during drying, creating deep dents that impair subsequent layer application
Solution Approach 1:
The patent applies parameter change by limiting the volatile solvent fraction to a maximum of 10% by volume. This reduces the layer thickness reduction during drying from 40-65% to a much smaller amount, preventing deep dent formation that would compromise the adhesion and application quality of subsequent decorative and surface layers.
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 significantly reduces or eliminates dents in the primer layer, allowing for improved decorative layer application and maintaining the cork's positive properties.
Implementation Method 1
During the drying or curing of the coating system, any volatile components present escape
Implementation Method 2
combined with UV-curing
Data Source
AI summary
A method for producing a floor panel comprising a carrier board, a cork layer, a primer and a decorative layer is disclosed. To achieve qualitatively improved decorative layers, a method is disclosed in which the cork layer is applied to the carrier board, in which, in order to form the primer, a coating system having a proportion of volatile components is applied to the cork layer, and in which the decorative layer is printed onto the primer.