PVC Panel Primer Layer Integration for Decorative Quality
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Solution Overview
Problem
Existing PVC floor coverings are costly and complex to produce, with limited durability and unsatisfactory decorative patterns, particularly due to the need for separate decorative papers and primer layers for improved adhesion.
Innovation Solution
A PVC panel with a polymerizable primer layer and decorative pattern printed directly onto the carrier layer, followed by a polymer layer with a hardness gradient, eliminating the need for separate decorative papers and using polymerizable inks for improved adhesion and curing, and a curtain coating process for primer application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate decorative paper layer is used, then decorative quality is improved, but device complexity and production costs increase
Solution Approach 1:
The patent combines the decorative pattern and the primer layer into a single integrated layer. The decorative pattern is printed directly onto the primer layer, eliminating the need for a separate decorative paper layer. This merging reduces production complexity while maintaining decorative quality through direct printing techniques.
Solution Approach 2:
The patent extracts and eliminates the separate decorative paper layer from the traditional multi-layer structure. By printing the decorative pattern directly onto the primer layer, the invention removes an unnecessary intermediate layer, simplifying the overall structure and production process while achieving the desired decorative effect.
2Reliability
If a primer layer is added for improved adhesion, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent merges the primer layer function with the decorative pattern layer. By printing the decorative pattern directly onto the primer layer, the invention combines adhesion promotion and decoration into a single integrated layer, maintaining reliability while reducing structural complexity.
Solution Approach 2:
The primer layer serves multiple functions simultaneously: it provides adhesion promotion for the polymer layer and carries the decorative pattern through direct printing. This multi-functionality eliminates the need for separate decorative layers, reducing complexity while maintaining or improving adhesion reliability.
3Ease of manufacture
If conventional coating methods are used, then ease of manufacture is maintained, but manufacturing precision and surface finish deteriorate
Solution Approach 1:
The patent replaces conventional mechanical coating methods with a printing process. By printing the decorative pattern directly onto the primer layer, the invention achieves superior surface finish quality and manufacturing precision while maintaining ease of manufacture through established printing technologies.
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 reduces production costs and complexity, enhances durability and decorative quality by achieving improved adhesion and surface finish with a hardness gradient, and extends panel service life through chemical crosslinking and abrasion-resistant particles.
Implementation Method 1
The polymer layer is generally preferably based on a polymerizable resin, such as in particular an acrylate resin... the curing of the primer layer and the polymer layer... Hardening or hardening of a polymer layer refers to the chemical reaction that takes place during polymerization
Implementation Method 2
two liquid, different polymer layers are applied wet-on-wet to the surface of a panel, so that the coating agents are partially mixed... the cured resulting coating having a hardness gradient due to the partial mixing
Data Source
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AI summary
The present invention relates to a panel (10), in particular a wall, ceiling or floor panel, comprising a carrier layer (12) based on PVC and a primer layer (17), wherein the primer layer comprises a decorative pattern (18) printed thereon, and a cured polymer layer (19) is provided over the primer layer and the decorative pattern. The primer layer has a basis weight of between 15 and 150 g/m². Furthermore, the present invention relates to a method for manufacturing such a panel, wherein the primer is applied as an aqueous acrylate system, preferably by means of a curtain coating process.