Matte Varnish via Excimer Radiation for Deep Grain
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Solution Overview
Problem
Current varnishing processes for floor and wall coverings fail to achieve a matte finish with good resistance to fouling and roughness, particularly on deep grains, and do not effectively form a barrier against volatile organic compounds, while also degrading the appearance of the graining and causing defects like stringing.
Innovation Solution
A process involving the sequential steps of depositing a varnish layer, pre-crosslinking under ultraviolet radiation from an LED lamp, tensioning with monochromatic excimer radiation, and full crosslinking under UV radiation, which allows for a varnish with low gloss and fine surface tension, suitable for deep grains and providing a barrier against volatile organic compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thin layer of varnish is applied to provide resistance to soiling and gloss, then durability and scratch resistance are improved, but the appearance of the surface graining is degraded and realism is reduced
Solution Approach 1:
The patent applies different treatments to different parts of the varnish layer: the bulk provides protection while the surface is selectively treated to maintain graining appearance. The excimer radiation treatment creates a crosslinked surface layer that preserves texture, while the overall thin layer maintains graining visibility.
Solution Approach 2:
The patent changes the chemical and physical parameters of the varnish through sequential radiation treatments. The excimer radiation at 172 nm creates a crosslinked surface with different properties than the uncured bulk, transforming the varnish from a simple protective coating to a multi-layer structure with differentiated functions.
2Manufacturing precision
If varnish is applied in droplets using inkjet printing to avoid matting agents, then application precision is improved, but the gloss is too high (greater than 90 BU) and a matte finish cannot be achieved
Solution Approach 1:
The patent replaces mechanical matting methods (physical abrasion, matting agents) with radiation-based chemical treatment. The excimer radiation induces crosslinking that creates a matte surface finish without requiring mechanical intervention or additive materials.
Solution Approach 2:
The patent changes the surface properties of the droplet-deposited varnish through excimer radiation treatment. The high-energy 172 nm radiation transforms the surface chemistry and topology, converting a high-gloss finish into a matte finish while preserving the precise droplet pattern.
3Illumination intensity
If monochromatic excimer radiation is applied to reduce gloss and create matte finish, then surface roughness is improved, but the varnish viscosity is too low to react uniformly and bright spots appear
Solution Approach 1:
The patent performs a preliminary UV curing step before the excimer radiation treatment. This pre-curing increases the varnish viscosity and creates a more uniform matrix that can withstand the excimer treatment without forming bright spots, ensuring uniform matte finish across the surface.
Solution Approach 2:
The patent uses a continuous sequential process where UV pre-curing is immediately followed by excimer radiation treatment. This continuous action ensures the varnish is in the optimal state for each treatment step, preventing defects and maintaining uniformity throughout the process.
4Reliability
If conventional UV curing is applied to achieve full crosslinking, then durability is improved, but volatile organic compound emissions are not sufficiently reduced and barrier effect is insufficient
Solution Approach 1:
The patent replaces conventional thermal or extended UV curing methods with high-energy excimer radiation at 172 nm. This substitution achieves complete crosslinking and VOC encapsulation in a single step, creating a superior barrier effect without the emissions associated with conventional curing.
Solution Approach 2:
The excimer radiation induces a phase transition in the varnish chemistry, transforming uncured resin into a fully crosslinked network. This chemical phase change creates an impermeable barrier that traps VOCs, achieving both durability and emission reduction simultaneously.
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 process achieves a matte varnish with a soft touch and low gloss, maintaining resistance to fouling and roughness, and significantly reduces volatile organic compound emissions, while preserving the relief structure and appearance of the graining.
Implementation Method 1
b) Expose the varnish to ultraviolet radiation under an LED lamp so as to pre-cure it
Implementation Method 2
c) Expose the varnish to monochromatic excimer-type radiation under an inert atmosphere so as to harden its surface
Implementation Method 3
d) Expose the varnish to ultraviolet radiation under a UV lamp so as to fully cross-cure it
Data Source
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AI summary
The invention relates to a method of varnishing a floor or wall covering, comprising at least steps consisting successively of: a) Depositing a first layer of varnish having a thickness of less than 1 mm on the covering, b) Exposing the varnish to ultraviolet radiation under an LED lamp so as to pre-crosslink it, c) Exposing the varnish to monochromatic excimer-type radiation under an inert atmosphere so as to harden its surface, d) Exposing the varnish to ultraviolet radiation under a UV lamp so as to fully crosslink it, in particular in its thickness.