Digital-Printed Floor Panel Lamination Against Wear-Layer Delamination
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Solution Overview
Problem
Existing floor panels made of supple synthetic materials, particularly vinyl tiles, face issues with delamination between the thermoplastic wear layer and digital print due to inadequate adherence, especially when using UV-based, solvent-based, or water-based inks, leading to potential dimensional alterations and wear at edges.
Innovation Solution
Incorporating a decorative digital print on a thermoplastic film with pigmented inks and a primer or adhesion layer, such as polyurethane hotmelt, polyamide hotmelt, or water-based primers, to enhance adherence between the print and a transparent PVC wear layer, which is laminated using a hot press treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thermoplastic wear layer is applied over a digital print on supple vinyl panels, then wear resistance is improved, but delamination occurs between the wear layer and print due to inadequate adherence
Solution Approach 1:
The patent introduces a primer layer as an intermediary between the digital print and the thermoplastic wear layer. This primer layer specifically enhances adhesion by creating a strong bonding interface that prevents delamination while allowing the wear layer to maintain its wear-resistant properties.
Solution Approach 2:
The patent creates a multi-layer composite structure consisting of the vinyl substrate, digital print, primer layer, and thermoplastic wear layer. Each layer is specifically designed to bond with adjacent layers, creating a composite material system where the whole is stronger than the sum of its parts, preventing delamination while maintaining wear resistance.
2Measurement precision
If UV-based or solvent-based inks are used for digital printing, then print resolution is improved, but dimensional alterations occur leading to delamination
Solution Approach 1:
The patent applies a primer layer before applying the thermoplastic wear layer to compensate for potential dimensional alterations in the printed substrate. This preliminary action creates a stable bonding interface that accommodates minor dimensional changes without causing delamination.
Solution Approach 2:
The patent modifies the chemical parameters of the primer layer to specifically address dimensional instability. The primer is formulated with adhesion promoters and flexible binding agents that can accommodate dimensional variations while maintaining strong bonding between layers.
3Strength
If edge areas of floor panels are subjected to wear, then mechanical durability is improved, but delamination occurs at edges compromising overall durability
Solution Approach 1:
The primer layer serves as a mediator that specifically strengthens the bonding at edge areas where wear is most likely to occur. This intermediary layer distributes stress more evenly across the interface, preventing delamination at critical edge zones while maintaining mechanical durability.
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
Enhances the adherence between the print and wear layer, reducing delamination risks and maintaining dimensional stability, while allowing for high print resolution and wear resistance.
Implementation Method 1
a primer or adhesion layer, such as polyurethane hotmelt, polyamide hotmelt, or water-based primers, to enhance adherence between the print and a transparent PVC wear layer
Implementation Method 2
which is laminated using a hot press treatment
Data Source
AI summary
A method for manufacturing a panel having a substrate, a decorative layer that includes a digital print, and a translucent or transparent wear layer may involve providing the substrate with the digital print by jetting one or more inks from a set of inks using a digital inkjet printer. The inks of the set of inks may include a binding agent. An additional spot color channel in the digital inkjet printer may be used to jet a colorless ink with an increased concentration of binder or binding agent.