Panel Coating Patterning by Digital Printing and UV Curing
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Solution Overview
Problem
Existing methods for manufacturing panels lack an efficient process to create textured surfaces with precise digital patterns and tactile-visual effects, particularly for flooring, wall coverings, ceiling coverings, and furniture applications.
Innovation Solution
A method involving digital printing of a liquid substance with different surface tension than the coating, followed by irradiation to cure the coating, creating a textured surface with distinct areas through repulsion and reaction between the substance and coating, allowing for varied thickness and visual-tactile effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a liquid coating is applied onto the substrate and then cured by irradiation, then a continuous protective layer is formed, but the manufacturing process requires separate steps for coating application and curing
Solution Approach 1:
The patent combines the coating application and curing steps into a single integrated process by applying a coating composition that contains both the liquid coating material and photopolymerization initiator, then irradiating with UV light to simultaneously cure the entire coating in one step, eliminating the need for separate coating and curing operations
Solution Approach 2:
The patent incorporates the photopolymerization initiator into the coating composition before application, preparing the coating in advance with all necessary components for immediate curing upon irradiation, thus enabling one-step processing without requiring additional initiator application steps
2Manufacturing precision
If a substance is digitally printed locally on the substrate before coating application, then patterned functionality is achieved, but the substance and coating must have compatible surface tensions to prevent defects
Solution Approach 1:
The patent modifies the surface tension parameters of either the digitally printed substance or the liquid coating through chemical composition adjustment, ensuring optimal compatibility and preventing defects such as pooling or dewetting, thereby enabling reliable patterned coating formation
3Manufacturing precision
If a non-curable or limited curable coating is applied over a digitally printed substance, then patterned curable regions are formed, but the non-curable coating requires additional substances to achieve curability at pattern locations
Solution Approach 1:
The patent creates local quality differences by applying a coating that is non-curable or limited curable in general, but becomes curable at specific patterned regions where it contacts the digitally printed substance, achieving spatially differentiated curability without requiring complex multi-layer structures
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 efficiently produces panels with finely textured, visually and tactually distinct areas, enhancing aesthetic appeal and providing precise pattern registration without requiring preformed structured sheets.
Implementation Method 1
the coating (12) and the substance (11) react with each other
Implementation Method 2
irradiating the upper side (3) so as to cure at least a part of the layer by irradiation
Implementation Method 3
the substance (19) makes the coating (17) curable by the irradiation at locations where they meet each other
Data Source
Figure 1~2
AI summary
A method of manufacturing a panel (1), comprising the steps of supplying a substrate (2) having an upper side (3), applying a layer onto the upper side (3) and subsequently irradiating the upper side (3) so as to cure at least a part of the layer by irradiation, hence forming the panel (1), wherein the layer comprises a liquid coating (12, 17) on substantially the entire upper side (3) and a substance (11, 19, 21) which is digitally printed locally on the upper side (3), wherein the substance (11, 19, 21) and the liquid coating (12, 17, 21) cooperate such that either the coating (12) and the substance (11) react with each other, whereas the substance (11) is a liquid that is printed on the upper side (3) before the coating (12) is applied and wherein the substance (11) and the coating (12) have different surface tensions, or the coating (17) is non-curable or only curable to a limited extent by the irradiation, whereas the substance (19) makes the coating (17) curable by the irradiation at locations where they meet each other.