Digitally Printed Floor Panel Coating for Strong Layer Adhesion
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Solution Overview
Problem
Existing wall or floor panels face challenges in achieving high stability while ensuring good manufacturability and adherence of layers, particularly under heavy loads.
Innovation Solution
A wall or floor panel comprising a plastic substrate with a decorative layer applied via digital printing and a decorative coating that includes covalent bonds formed by thiol groups and carbon-carbon double bonds, as well as epoxy groups, ensuring strong adhesion between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional coating layers are used in wall or floor panels, then the panel structure is simple and easy to manufacture, but the adhesion between layers is insufficient and the panel cannot withstand heavy loads
Solution Approach 1:
The patent applies composite materials by creating a multi-layer coating system where each layer has specific chemical compositions. The first coating layer contains thiol groups that form covalent bonds with the substrate, the second layer contains carbon-carbon double bonds that react with the first layer, and the third layer contains epoxy groups that bond to the second layer. This composite structure achieves superior inter-layer adhesion while maintaining manufacturability through standardized application processes.
Solution Approach 2:
The patent changes the chemical parameters of the coating layers by introducing specific functional groups (thiol, carbon-carbon double bond, epoxy group) at controlled concentrations. The thiol group content in the first layer is optimized to ensure sufficient covalent bonding with the substrate, while the carbon-carbon double bond content in the second layer is adjusted to achieve optimal cross-linking density. These parameter changes enable the coating system to withstand heavy loads while preserving ease of manufacture through controlled chemical composition.
2Reliability
If multiple coating layers with complex chemical bonds are applied to improve stability, then the panel can withstand heavy loads, but the manufacturing process becomes more complex
Solution Approach 1:
The patent segments the coating system into three distinct functional layers, each responsible for specific bonding tasks. The first layer segments the bonding function to the substrate via thiol groups, the second layer segments the cross-linking function via carbon-carbon double bonds, and the third layer segments the top-layer adhesion function via epoxy groups. This segmentation allows each layer to be optimized independently while maintaining overall manufacturing simplicity through a systematic application process.
Solution Approach 2:
The patent introduces the second coating layer containing carbon-carbon double bonds as an intermediary between the first layer (thiol groups) and the third layer (epoxy groups). This intermediary layer facilitates the chemical bonding chain by providing reactive sites that connect the substrate-bonding first layer with the top-layer-adhering third layer. The intermediary structure enables reliable stress transfer across all layers while preserving manufacturing ease through a standardized multi-step coating 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
The panel achieves high stability and ease of manufacturing with excellent adhesion properties, capable of withstanding heavy loads and reducing manufacturing complexity.
Implementation Method 1
covalent bonds formed by the reaction of a thiol group and a carbon-carbon double bond
Implementation Method 2
covalent bonds formed by the reaction of a thiol group and an epoxy group
Implementation Method 3
covalent bonds formed by a reaction between a carbon-carbon double bond and an epoxy group
Implementation Method 4
covalent bonds exist between the first decorative coating layer and the second decorative coating layer
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a wall or floor panel (10) comprising a plastic carrier (12), a decorative layer (14) applied to the plastic carrier (12) by means of digital printing, a decorative coating (20), and a top layer (16), characterized in that the decorative coating (20) comprises: - a first decorative coating layer (22) and a second decorative coating layer (24), wherein - in the first decorative coating layer (22) there are covalent bonds formed by the reaction of a thiol group and a carbon-carbon double bond, covalent bonds formed by the reaction of a thiol group and an epoxy group, and covalent bonds formed by a reaction between a carbon-carbon double bond and an epoxy group, wherein - the first decorative coating layer (22) comprises covalent cross-links between compounds present in the first decorative coating layer (22).and wherein - covalent bonds exist between the first decorative coating layer (22) and the second decorative coating layer (24).