Resilient Flooring With UV-Cured Ink Tie-Layer Adhesion
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Solution Overview
Problem
Conventional resilient floor coverings produced using UV-cured inks face challenges in forming a composite laminated structure due to the inability of additional polymer layers to adhere to the ink layer.
Innovation Solution
A resilient floor covering design that includes a backing portion, a decorative portion with a digitally printed ink layer, a tie layer with an adhesive composition, and a wear layer, where the tie layer facilitates strong adhesion between the ink layer and the wear layer, allowing for the formation of a conventional laminated structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If UV-cured inks are used for digital printing, then manufacturing efficiency and design flexibility are improved, but adhesion of additional polymer layers to the ink layer deteriorates
Solution Approach 1:
A tie layer comprising a polyol polymer is introduced between the UV-cured ink layer and the additional polymer layers (such as wear layers). This tie layer acts as an intermediary that provides both chemical compatibility with the UV-cured ink and sufficient adhesion properties for the overlying polymer layers, thereby resolving the adhesion problem while maintaining the benefits of UV-cured digital printing
Solution Approach 2:
The flooring product is structured as a composite laminate comprising multiple distinct layers: the UV-cured ink layer, the polyol-based tie layer, and additional polymer layers. This composite structure allows each layer to perform its specific function - the UV-cured layer provides design flexibility and rapid curing, while the polyol tie layer provides the necessary adhesion interface
2Adaptability or versatility
If UV-cured inks are used for digital printing, then color variation and design complexity are improved, but formation of composite laminated structure deteriorates
Solution Approach 1:
The polyol tie layer serves as a universal intermediary interface that enables lamination of various types of polymer layers (wear layers, protective layers, etc.) onto the UV-cured ink layer. This mediator layer maintains the ease of forming composite structures while allowing the UV-cured ink layer to retain its full design flexibility and color variation capabilities
3Strength
If a tie layer is added to improve adhesion, then adhesive properties are improved, but device complexity increases
Solution Approach 1:
The tie layer is applied specifically and locally only where adhesion is required - at the interface between the UV-cured ink layer and the additional polymer layers. This localized application provides the necessary adhesion function without unnecessarily increasing the complexity of the entire flooring structure
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 enables the formation of a resilient floor covering with high adhesive properties between the ink and wear layers, overcoming the limitations of UV-cured inks and allowing for the creation of a composite laminated structure.
Implementation Method 1
the Ultra Violet (UV) cured inks that are often used in the digital printing to form an ink layer
Implementation Method 2
a tie layer with an adhesive composition, wherein the tie layer substantially overlies the decorative portion such that at least a portion of the second surface of the tie layer contacts and adheres to the first surface of the ink layer
Data Source
AI summary
Described herein are resilient floor coverings produced by using digitally printed UV-cured inks and exhibiting high adhesion properties between an ink layer and a wear layer. Also described herein are methods for manufacturing same. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present invention.