Printed linoleum-based sheet material
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Solution Overview
Problem
Conventional methods for producing patterned linoleum floor coverings are limited by restrictive design options, low production flexibility, and the inability to achieve high-resolution or photorealistic designs due to the direct mixing and rolling process, which also results in insufficient adhesion and environmental concerns with halogen-containing materials.
Innovation Solution
A linoleum-based printed sheet material comprising a base layer, a primer layer, and a highly resistant top layer with inorganic particles, allowing for decoupling of color and design production, enabling flexible and high-resolution digital printing with renewable materials and improved adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If colored mixed masses are poured directly into a calender gap and rolled out, then production process is simple, but longitudinal structures result and design options are severely restricted
Solution Approach 1:
The patent divides the production process into separate stages: base layer production without colorants, followed by separate printing of color designs. This segmentation allows the base layer to be produced simply while the design layer provides unlimited design options through digital printing techniques.
Solution Approach 2:
The base layer is produced in advance without colorants, allowing it to be ready for subsequent printing. This preliminary production of the neutral base enables flexible design changes and high-resolution printing without reproducing the entire linoleum sheet.
2Adaptability or versatility
If scattering technique is used for color designs, then special color patterns can be achieved, but effort is no longer justifiable and quick pattern changes are not allowed
Solution Approach 1:
The manual scattering technique is replaced with digital printing systems that use digital files to control color application. This substitution eliminates manual effort while enabling rapid pattern changes through software updates, maintaining design versatility while dramatically improving productivity.
3Adaptability or versatility
If scattering technique is used for color designs, then patterns can be applied, but resolution is coarse and repeat accuracy is limited
Solution Approach 1:
Digital printing technology replaces the imprecise scattering method with computer-controlled color deposition. This enables high-resolution printing with exact repeat accuracy by digitally reproducing design files, achieving photorealistic representations while maintaining design flexibility.
4Reliability
If protective films are applied to reduce abrasion, then abrasion resistance is improved, but adhesion is insufficient and upstanding edges occur
Solution Approach 1:
The patent merges the protective top layer with the color design layer into a single integrated printing layer. This combination ensures that the protective coating is applied uniformly over the printed surface, eliminating adhesion problems and upstanding edges while maintaining both protection and design integrity.
Solution Approach 2:
The top layer is formulated as a composite material combining protective polymers with color pigments and binding agents. This composite structure provides both the required abrasion resistance and strong adhesion to the base layer, eliminating the need for separate protective films.
5Reliability
If maturing time is waited for linoleum production, then material properties are achieved, but production flexibility is severely limited
Solution Approach 1:
The production process is segmented into base layer production (requiring maturing) and separate printing operations. This allows the base layer to mature while design changes can be prepared in advance, and printing can be performed quickly once the base is ready, significantly improving production flexibility.
Solution Approach 2:
Design files and printing preparations are completed in advance while the base layer is maturing. This preliminary preparation of digital designs and printing parameters enables rapid production once the base layer is ready, minimizing the impact of maturing time on overall production flexibility.
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 solution provides a high degree of creative freedom in design, increased production flexibility, and enhanced durability with improved adhesion and abrasion resistance, eliminating the need for environmentally harmful materials.
Implementation Method 1
the top layer is a heat seal layer containing inorganic particles
Data Source
AI summary
The invention relates to a linoleum or korkment-based sheet material comprising a base layer made of linoleum or korkment, a printed layer and a cover layer which has high abrasion resistance and adhesion permanence, and to a method for producing the sheet material according to the invention.