PVC Covering Matte Varnish Curing for Stain Resistance
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Solution Overview
Problem
Existing floor and wall coverings face challenges in achieving a matte appearance while maintaining high chemical resistance to stains and flexibility, as conventional varnishing processes often compromise between gloss effect and stain resistance.
Innovation Solution
A varnishing process involving the production of a matte varnish, deposited in a thin layer, pre-densified by UV micro-dose exposure, followed by cross-linking under EXCIMER and ultraviolet radiation in an inert atmosphere, ensuring a low gloss level (8-20%) and enhanced chemical resistance to stains like hospital disinfectants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If matte varnish is used to achieve low gloss effect, then the shine is reduced to between 8 and 20%, but the resistance to stains deteriorates when using matting systems
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the varnish formulation and the radiation parameters (wavelength, dose, atmosphere) during curing. Specifically, it uses a multi-stage UV curing process with different radiation conditions (initial UV, then EXCIMER monochromatic radiation at 172nm, then final UV) to achieve a crosslinked network that provides both matte appearance and high chemical resistance to stains.
Solution Approach 2:
The patent employs composite materials by creating a complex crosslinked polymer network through multi-stage radiation curing. The varnish contains multiple functional components that undergo different curing mechanisms: initial photopolymerization, then EXCIMER-induced crosslinking, and final UV curing. This composite curing approach produces a surface layer with optimized properties combining matte finish and stain resistance.
2Productivity
If conventional UV photopolymerization is used, then the varnish cures efficiently, but the chemical resistance to hospital disinfectants such as iodized alcohol deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the curing process into distinct stages: initial UV photopolymerization, intermediate EXCIMER monochromatic radiation treatment, and final UV crosslinking. Each stage performs a specific function - the initial UV starts polymerization, the EXCIMER stage creates dense crosslinks for chemical resistance, and the final UV completes the network. This segmented approach ensures both curing efficiency and superior chemical resistance to disinfectants.
Solution Approach 2:
The patent uses preliminary action by applying EXCIMER monochromatic radiation at 172nm before final UV curing. This intermediate treatment pre-densifies the polymer network and creates a highly crosslinked structure that provides exceptional chemical resistance to hospital disinfectants. The preliminary EXCIMER treatment prepares the surface to withstand subsequent chemical exposure while maintaining curing efficiency.
3Manufacturing precision
If the varnish layer is made thin and regular, then the surface appearance is improved, but the flexibility adapted to resilient floor covering deteriorates
Solution Approach 1:
The patent applies parameter changes by optimizing the varnish formulation parameters (resin type, crosslinking density, plasticizer content) and curing parameters (radiation dose, atmosphere, temperature). The specific EXCIMER radiation at 172nm with controlled dose creates a crosslinked network that maintains flexibility while achieving a thin, regular surface. The inert atmosphere (nitrogen) during curing also influences the polymer network structure to balance surface quality and flexibility.
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 significantly reduces stains, maintains desired gloss, and provides flexibility and ease of maintenance, achieving excellent chemical resistance and scratch resistance while ensuring the surface treatment meets market demands.
Implementation Method 1
expose the assembled assembly for surface treatment by cross-linking under monochromatic radiation of the EXIMER lamp type
Implementation Method 2
second stage of crosslinking by ultraviolet radiation
Data Source
Figure 1~2
Figure 3~4
AI summary
The process comprises producing matt varnish for depositing on a thin layer, regulating a floor coating on a constitutive structure for treating its surface by reticulation using excimer type monochromatic radiation lamp (14), and cross-linking the floor and wall coatings in a chamber under inert atmosphere using UV light. The matt varnish is deposited in the thin layer having a thickness of 8-20 mu m. Independent claims are included for: (1) an installation for varnishing floors and flexible walls; and (2) a flexible floor and wall coating.