Abrasion-Resistant Multilayer Panel with Scattered Particles
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Solution Overview
Problem
Existing methods for producing SPC floor coverings result in products with poor transparency and higher costs due to complex manufacturing processes and the use of multiple films as wear layers.
Innovation Solution
A method involving the application of a base coat, direct printing of a decorative layer, uniform scattering of abrasion-resistant particles, and the application of multiple cover layers using hot melt adhesives, followed by curing, to produce an abrasion- and water-resistant multilayer panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thick wear film is used to achieve higher wear class, then abrasion resistance is improved, but cost and transparency deteriorate
Solution Approach 1:
The patent applies a composite material approach by combining a thermoplastic wear layer with dispersed abrasion-resistant particles (such as aluminum oxide, silicon carbide, or corundum). This composite structure provides enhanced abrasion resistance without requiring increased film thickness, thereby maintaining transparency and reducing material costs while achieving higher wear classes.
Solution Approach 2:
The invention implements local quality enhancement by concentrating abrasion-resistant particles specifically within the wear layer where they are most needed for friction resistance. This localized reinforcement allows the base film to remain thin and transparent while providing superior abrasion resistance only in the contact zone, optimizing both optical and mechanical properties.
2Strength
If a thick wear film is used to achieve higher wear class, then abrasion resistance is improved, but transparency deteriorates
Solution Approach 1:
The composite wear layer with dispersed abrasion-resistant particles provides the necessary mechanical protection while maintaining optical clarity. The particles are distributed throughout the thermoplastic matrix in a manner that minimizes light scattering, allowing the film to remain thin and transparent even at higher wear classes.
3Strength
If multiple films are used as wear layer, then abrasion resistance is improved, but device complexity and cost increase
Solution Approach 1:
The patent merges the functions of multiple separate wear films into a single integrated composite wear layer. By incorporating abrasion-resistant particles directly into one thermoplastic film during manufacturing, the process eliminates the need for separate application and bonding of multiple films, thereby simplifying the manufacturing process, reducing production complexity, and lowering costs while maintaining superior abrasion resistance.
4Strength
If multiple films are used as wear layer, then abrasion resistance is improved, but production time and cost increase
Solution Approach 1:
The composite wear layer is manufactured as a single integrated product in one continuous process, eliminating the multiple steps required for applying, positioning, and bonding separate films. This consolidation significantly reduces production time, increases manufacturing efficiency, and improves productivity while delivering the same or superior abrasion resistance performance.
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 enhances the efficiency of producing SPC floor coverings while maintaining technical properties, reducing costs, and improving transparency by simplifying the manufacturing process and eliminating the need for multiple films.
Implementation Method 1
Applying at least one base coat comprising at least one hot melt adhesive to the surface of the plastic carrier plate; Applying at least one first cover layer comprising at least one hot melt adhesive to the imprinted decorative layer; Applying at least one second cover layer comprising at least one hot melt adhesive to the layer of scattered abrasion resistant particles; Applying at least one lacquer layer
Implementation Method 2
Curing of the layer structure
Data Source
AI summary
It is provided a method for producing an abrasion- and water-resistant multilayer panel, in particular an abrasion- and water-resistant flooring panel, including the steps: providing at least one plastic carrier plate, in particular a PVC carrier plate; applying at least one base coat to the surface of the plastic carrier plate; printing the plastic carrier plate by direct printing to form a decorative layer; applying at least one first cover layer to the printed decorative layer; uniformly scattering abrasion-resistant particles onto the at least one cover layer applied to the decorative layer; applying at least one second covering layer to the layer of scattered abrasion-resistant particles; optionally, introducing a structure into the at least second cover layer, applying at least one lacquer layer, and curing the layer structure.