Matte-Free UV Curing for Decorative Floor Panels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional UV curing systems for decorative floor and wall panels face challenges such as difficulty in achieving a matte surface, sedimentation of matting agents, increased defect rates, and inefficiencies due to high radiation intensity and thermal issues, leading to inadequate slip resistance and surface texture.
Innovation Solution
A method involving two sequential irradiation steps at different wavelengths within an inert environment for curing the coating layer, eliminating the need for matting agents and reducing volatile compound emissions, while maintaining high energy efficiency and achieving desired surface roughness and slip resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If matting agents are embedded in the coating layer to achieve a matte surface, then the surface gloss is reduced, but the particles are easily removed by friction causing glossy spots and increased defect rates
Solution Approach 1:
The invention extracts and eliminates matting agents from the coating composition entirely. Instead of using inorganic or ceramic particles to achieve matte surfaces, the patent employs a matting-free UV coating formulation that cures to provide both matte appearance and durable surface properties without embedded particles that can be dislodged during use.
Solution Approach 2:
The invention changes the chemical composition parameters of the UV coating by formulating it without matting agents. The coating uses specific monomer and oligomer combinations with controlled molecular weights and functional groups that enable matte surface formation through the coating matrix itself rather than through embedded particles, fundamentally changing how matting is achieved.
2Productivity
If high radiation intensity is used to improve curing efficiency, then the curing speed increases, but the lamps decay faster and reflectors warp due to thermal expansion
Solution Approach 1:
The invention employs a multi-stage UV curing process with periodic action, using different UV lamp types for different stages. The first stage uses a UVB lamp for initial curing, followed by a UVA lamp for final curing. This periodic approach distributes thermal load over time and allows cooling intervals, preventing reflector warping and lamp decay while maintaining high overall curing efficiency.
Solution Approach 2:
The curing process is segmented into two distinct stages using different wavelength UV lamps. The UVB stage (280-315 nm) performs initial curing of the coating, while the UVA stage (315-400 nm) completes the curing process. This segmentation allows each lamp type to operate at optimal intensity for its specific function without the continuous thermal stress that would damage a single high-intensity lamp system.
3Ease of operation
If inorganic particles are used to achieve slip resistance, then the surface texture is improved, but the particles abrade during use causing gloss deterioration and increased defect rates
Solution Approach 1:
The invention extracts and removes all inorganic matting and slip resistance particles from the coating formulation. Instead, it achieves both matte appearance and slip resistance through the organic polymer matrix composition and surface microstructure formed during curing, eliminating the abrasion problem associated with inorganic particles while maintaining functional performance.
Solution Approach 2:
The invention uses a composite organic coating system combining specific monomers and oligomers that create an integrated matrix providing both matte finish and slip resistance. The coating forms a homogeneous organic composite without inorganic fillers, where the polymer network itself provides the surface properties needed for both aesthetics and safety.
4Shape
If volatile components are introduced to increase shrinkage degree during curing, then the surface roughness is improved, but the emission of volatile compounds increases which is harmful to health and environment
Solution Approach 1:
The invention changes the chemical composition parameters by using high molecular weight oligomers with specific functional groups that provide controlled shrinkage during curing without requiring volatile components. The coating formulation uses monomers and oligomers selected for their shrinkage characteristics, achieving the necessary volume contraction for surface roughness development through polymerization chemistry rather than volatile evaporation.
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 method results in a fully cured coating with enhanced surface roughness, qualified slip resistance, and improved energy efficiency, reducing defect rates and maintaining gloss retention, with a 40% increase in surface scratch resistance and microscratch resistance.
Implementation Method 1
UV curing is a photochemical process that involves irradiating transparent UV curable coatings generally comprising acrylic monomers and oligomers as well as photo-initiators with UV rays which creates a cross-linking reaction that instantly or nearly instantly cures or dries the coating
Data Source
AI summary
The invention relates to a decorative floor panel or wall panel with at least one core layer; at least one decorative surface comprising at least one decorative print; and at least one coating layer provided upon the decorative surface. The at least one coating layer comprises at least one primer layer and at least one top coating layer. The at least one top coating layer comprises at most 0.5 wt % of matting agents, wherein the gloss or sheen level of the at least one top coating layer is at most 4 Gu. The panel comprises a texture on the top surface with the texture comprising a plurality of cavities or recesses forming a first and second surface area, and the first surface area and/or the second surface area have a gloss level difference of less than 10 Gu. The sum of the first and second surface area forms the top surface area.