Solvent-Free Inkjet Floor Covering Bonding Layer
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Solution Overview
Problem
The existing methods for manufacturing floor coverings using polyvinyl chloride (PVC) face challenges with high manufacturing costs due to the need for multiple bulky and expensive engraved metal cylinders for rotogravure printing, and solvent-based inkjet printing poses environmental pollution risks and compatibility issues leading to delamination.
Innovation Solution
A method involving a multilayer structure with a decorative printing layer created using solvent-free liquid pigment ink via inkjet printing, followed by energy-induced solidification and application of a chemically compatible bonding layer to prevent delamination, reducing manufacturing costs and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rotogravure printing with multiple engraved metal cylinders is used, then manufacturing precision and durability are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces physical metal cylinders with digital pattern files that can be stored and reproduced indefinitely. The inkjet printing system uses digital images to guide the deposition of pigment ink, eliminating the need for physical copying masters (metal cylinders) while maintaining pattern fidelity through digital reproduction
Solution Approach 2:
The patent substitutes the mechanical rotogravure printing system with an inkjet printing system that uses digitally controlled droplet ejection. This replaces the mechanical engraving and rolling process with a non-contact, digitally guided liquid deposition process, eliminating bulky metal cylinders entirely
2Ease of manufacture
If solvent-based inkjet printing is used, then ease of manufacture is improved, but environmental harm and chemical compatibility issues worsen
Solution Approach 1:
The patent fundamentally changes the chemical parameter of the ink composition by eliminating organic solvents entirely. It uses water as the sole carrier for pigment particles, transforming the ink from an organic-based formulation to an aqueous-based formulation, thereby eliminating VOC emissions while maintaining printability
Solution Approach 2:
The patent employs a disposable, environmentally benign carrier (water) that evaporates completely after depositing the pigment. Unlike persistent organic solvents, water is non-toxic, rapidly evaporates without harmful residues, and can be replaced indefinitely without environmental accumulation concerns
3Object-generated harmful factors
If solvent-free pigment ink is used, then environmental harm is reduced, but adhesion strength deteriorates due to chemical incompatibility
Solution Approach 1:
The patent introduces a primer layer as an intermediary substance between the pigment ink and the wear layer. This primer acts as a chemical bridge that bonds to both the inorganic pigment particles and the organic polymer matrix of the wear layer, enabling adhesion without requiring direct chemical compatibility between the ink and substrate
Solution Approach 2:
The patent creates a composite bonding interface consisting of multiple components: the primer layer contains adhesion promoters, coupling agents, and compatible polymers that combine properties to bond with both the aqueous pigment ink and the PVC-based wear layer, forming a multi-phase composite structure for enhanced adhesion
4Productivity
If quick-drying volatile solvents are used, then productivity is improved, but environmental harm increases
Solution Approach 1:
The patent changes the physical parameter of the carrier liquid from volatile organic compounds to water, which has different evaporation characteristics. Water evaporates quickly at room temperature through natural convection and diffusion, providing sufficient drying speed for floor covering production without the environmental harm of VOCs
Solution Approach 2:
The patent converts the typically harmful property of rapid evaporation (which causes VOC emissions) into a beneficial process by using water as the carrier. The rapid evaporation of water provides quick drying without environmental harm, turning what is usually a problematic characteristic into an advantage
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 allows for cost-effective and flexible pattern changes while ensuring environmental sustainability and long-term adhesion of the layers, avoiding delamination and VOC emissions.
Implementation Method 1
supplying energy to change the state of the decorative printing layer from a liquid to a solid state
Data Source
Figure 1A~1F
Figure 2A~2F
Figure 3A~3D
AI summary
The present invention relates to a flexible floor covering comprising a multilayer structure including at least one wear layer (1), a decorative printing layer (2) and a support layer (3), notable in that it includes at least one bonding layer (4) linked to the decorative printing layer (2) consisting of a solvent-free pigment ink layer deposited by an inkjet printer and linked to the underside of the wear layer (1) or to the upper side of the support layer (3).