Multi-colored Decorative Laminate with UV Luminescence
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Solution Overview
Problem
Conventional decorative laminates with photoluminescent materials can only display a single color image or pattern when exposed to ultraviolet light, limiting their applications, and the aluminum oxide in overlay layers causes undesirable scuffing and wear to bowling balls and shoes.
Innovation Solution
A decorative laminate comprising a core layer, a print layer, a high-wear overlay layer with a single photoluminescent color, a luminescent layer with multiple colored patterns, and a clear overlay layer, where the luminescent layer absorbs ultraviolet light, making the single color of the high-wear overlay layer invisible, and all layers are laminated under heat and pressure to create a durable and visually enhanced surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminum oxide is added to the overlay layer to improve wear resistance, then the durability of the laminate is improved, but it causes undesirable scuffing and wear to bowling balls and shoes
Solution Approach 1:
The harmful aluminum oxide particles are extracted and removed from the overlay layer. The patent replaces aluminum oxide with a different composition that provides wear resistance without causing scuffing and wear to bowling balls and shoes, thus eliminating the harmful effect while preserving the beneficial durability property.
2Ease of manufacture
If a single color photoluminescent material is used in the overlay layer, then the manufacturing process is simplified, but the visual information and application versatility are limited
Solution Approach 1:
The photoluminescent function is segmented into two separate layers: a first overlay layer with a single color photoluminescent material for durability, and a second overlay layer with multiple color photoluminescent materials for visual information. This segmentation allows each layer to specialize in one function, maintaining manufacturing simplicity while achieving multi-color visual capability.
Solution Approach 2:
The laminate uses a composite structure with multiple overlay layers, each containing different photoluminescent materials. The first overlay layer contains a single color photoluminescent material for wear resistance, while the second overlay layer contains multiple color photoluminescent materials for enhanced visual information, creating a composite material system that combines both benefits.
3Loss of information
If multiple colored photoluminescent patterns are incorporated into a single overlay layer, then visual information is enhanced, but the manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into two separate overlay layer applications. The first overlay layer is applied with a single color photoluminescent material for durability, and the second overlay layer is applied with multiple color photoluminescent materials for visual information. This segmentation simplifies manufacturing by avoiding the complexity of mixing and coordinating multiple colors in a single layer.
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 allows for multiple colored patterns to be visible simultaneously under ultraviolet light, enhancing safety and enjoyment while reducing wear and tear on contacting items, and maintaining a flat, balanced construction.
Implementation Method 1
The luminescent layer has a plurality of patterns printed thereon with different color photoluminescent materials which are each of a different color than the single color of the high-wear overlay layer such that the patterns of different colors are simultaneously visible when exposed to ultraviolet light
Implementation Method 2
the patterns of different colors are simultaneously visible when exposed to ultraviolet light such that the different colors in the luminescent layer block from view the single color of the high-wear overlay layer in the areas of the patterns in the overlay layer
Implementation Method 3
The core layer, the decorative layer and, when utilized, the overlay layer, are typically stacked in a superimposed relationship, between steel press plates and subjected to elevated pressure and temperature for a time sufficient to cure the laminating resins impregnating the respective layers
Data Source
AI summary
A decorative laminate, and method for making the same, includes a core layer, a print layer, an overlay layer, and a luminescent layer. The print layer includes patterns printed thereon using conventional ink. In some embodiments, the overlay layer is impregnated with a resin that includes photoluminescent material of a single color which, when exposed to UV light, causes the single color to be visible throughout. The luminescent layer includes patterns of photoluminescent materials of different colors. In the embodiments where the overlay layer includes a resin with a photoluminescent material, the different colored patterns of the luminescent layer are simultaneously visible with the single color of the overlay layer when exposed to UV light.