Pressable Elastomeric Polyurethane Coatings for Simpler Panel Finishing
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Solution Overview
Problem
Existing methods for coating finished panel constructs are complex and can lead to substrate degradation, and there is a need for an alternative approach to enhance appearance, feel, sound attenuating properties, and wear capabilities.
Innovation Solution
Applying a liquid coating material to a panel surface, allowing it to dry, and then pressing under heat and pressure to crosslink and bond the coating to the panel, using elastomeric resin-based materials, preferably water-borne polyurethane-based resin, to create a coated panel with improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional coating methods are used on finished panel constructs, then coating application is possible, but the process becomes complex and substrate degradation occurs
Solution Approach 1:
The invention applies coating material to the panel construct before final finishing operations. By performing the coating operation earlier in the manufacturing sequence, when the panel is still in a more accessible state, the process becomes simpler and avoids degradation issues that arise from attempting to coat finished surfaces with complex multi-step procedures
2Strength
If multiple coating layers are applied to enhance wear capabilities, then durability improves, but processing time and complexity increase
Solution Approach 1:
The invention uses a composite coating system comprising multiple layers with different functions: a primer layer for adhesion, intermediate layers for build and properties, and a topwear layer for durability. This composite approach achieves superior wear resistance while optimizing processing time by allowing parallel preparation of different layers and using accelerated curing methods
3Reliability
If elastomeric resin-based coating is applied, then sound attenuating properties improve, but curing and bonding complexity increases
Solution Approach 1:
The invention controls the curing process of elastomeric resin coatings by carefully managing parameters such as temperature, humidity, and curing time. The coating formulation is designed to cure at controlled rates, allowing the complex elastomeric polymerization process to proceed systematically, achieving sound attenuation properties without unmanageable process complexity
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
Results in coated panels with enhanced appearance, feel, sound attenuating properties, and wear capabilities, while avoiding the complexity and substrate degradation issues of traditional methods.
Implementation Method 1
applying one or more layers of a preferably liquid coating material to a surface of a panel construct, preferably with drying of each of said layers of coating material after each coating layer application
Implementation Method 2
subsequently pressing the coated panel construct under conditions of heat and pressure, for sufficient time to cure and crosslink said coating material, and bond said coating material to the surface of the panel construct
Data Source
AI summary
A panel and a panel production method are provided wherein an elastomeric coating, and preferably, a water-based elastomeric polyurethane coating, is applied to a pre-existing, finished panel construct, by pressing the coating onto the panel construct, and thereby bond the coating to the surface of the panel construct. The method is used to produce enhanced panels which can be used in the production of flooring materials, wall panels, furniture, countertops, and the like. The resultant panels typically have an enhanced surface that protects the surface layer of the panel construct. The coated panel can also be made abrasion resistant, and can also be enhanced so as to provide better acoustical properties while providing a soft touch, haptic surface.