Foamed PVC Coated Panel Wear Resistance and Transparency
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Solution Overview
Problem
Existing panel manufacturing techniques face challenges in achieving flexibility, deep structures, and adequate protection of printed motifs against wear and moisture, while also maintaining transparency and avoiding issues like ticking sounds and high energy consumption.
Innovation Solution
The use of foamable synthetic materials, such as polyvinyl chloride, applied in a soft condition over a substrate, which can be structured to form thick, transparent protective layers that adhere well to UV inks and allow for deep structures without deforming the substrate, and can be cured using simple techniques with minimal energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a protective layer composed of UV-hardening or electron beam-hardening lacquer is used, then wear resistance is improved, but the material cost and manufacturing complexity increase
Solution Approach 1:
The patent changes the material parameter from traditional lacquer to polyvinyl chloride (PVC) compound, which can be cured at lower temperatures and with simpler methods. The PVC compound maintains wear resistance while allowing for easier processing and reduced manufacturing complexity through alternative curing mechanisms.
Solution Approach 2:
The patent employs a cost-effective PVC compound formulation that replaces expensive specialized lacquers. The material achieves the required protective function at lower material cost and with simpler application processes, effectively substituting high-cost materials with more economical alternatives.
2Strength
If thermohardening resin is used for the protective layer, then wear resistance is improved, but the motif visibility deteriorates and the layer becomes cold to the touch
Solution Approach 1:
The patent changes the material from thermohardening resin to polyvinyl chloride compound, which offers different thermal and optical properties. The PVC compound maintains wear resistance while improving transparency for better motif visibility and providing more favorable tactile properties.
Solution Approach 2:
The patent uses a composite PVC compound formulation that combines the wear-resistant properties needed for protection with the optical clarity required for motif visibility. The composite material integrates multiple functions: protection, transparency, and tactile comfort in a single layer.
3Shape
If cellulose fibers are blended into the coating material to enable thicker layers, then structural depth is improved, but motif transparency deteriorates
Solution Approach 1:
The patent changes the filler material from cellulose fibers to a fine pigment mixture compatible with PVC. This allows the formation of thick protective layers with deep structures while maintaining motif transparency, as the fine pigment particles do not scatter light as much as cellulose fibers.
Solution Approach 2:
The patent creates a porous structure within the PVC compound that allows for deep structural formation while maintaining light transmission. The porous architecture provides structural depth without blocking the view of the underlying motif.
4Strength
If thermohardening resin is used for curing, then wear resistance is improved, but energy consumption increases and deep structures are difficult to realize
Solution Approach 1:
The patent changes the curing mechanism from high-energy thermohardening to lower-energy PVC curing processes. The PVC compound can be cured at lower temperatures and with simpler methods, reducing energy consumption while maintaining wear resistance and enabling deep structure formation.
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 enables the creation of coated panels with improved wear resistance, reduced ticking sounds, and enhanced transparency, allowing for deep structures and flexible application methods that protect the motif effectively while maintaining substrate integrity.
Implementation Method 1
said polyvinyl chloride paste is gelled or otherwise foamed or hardened while being present on the substrate
Implementation Method 2
comprises a foamable or foamed synthetic material, more particularly comprises polyvinyl chloride and plasticizer
Data Source
Figure 1~5
Figure 6~8
AI summary
Coated panel (1) of the type comprising at least a substrate (2) and a top layer (3) with a printed motif, said top layer being provided on this substrate (2), wherein said top layer (3) also comprises a transparent or translucent synthetic material layer (7), which is provided above said printed motif, characterized in that said top layer (3), and preferably at least said transparent or translucent synthetic material layer (7), comprises a foamable or foamed synthetic material.