Thermoplastic Floor Panel Printing with Metal Salt Primer
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Solution Overview
Problem
Existing methods for printing decorative patterns on thermoplastic materials, such as Luxury Vinyl Tiles and Planks, face challenges with aqueous inks bleeding and poor quality prints, and the use of UV or solvent-based inks is environmentally unfavorable, while also affecting the bonding between layers.
Innovation Solution
A method involving a primer with a metal salt is applied to the thermoplastic carrier surface before printing, which precipitates or agglomerates the ink pigment, preventing bleeding and ensuring high-quality prints with aqueous pigment ink compositions without compromising the bonding between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If aqueous ink is used for printing on thermoplastic surface, then environmental friendliness is improved, but print quality deteriorates due to ink bleeding
Solution Approach 1:
A primer layer comprising metal salt is introduced as an intermediary between the thermoplastic carrier and the aqueous ink. The primer absorbs the aqueous ink and precipitates the pigment, preventing bleeding while maintaining environmental friendliness of aqueous inks
Solution Approach 2:
The surface properties of the carrier are changed by applying a primer layer with different chemical composition (metal salt) than the carrier itself. This parameter change enables the surface to interact properly with aqueous ink, allowing precipitation and fixation of pigment particles
2Manufacturing precision
If UV curable inks or solvent based inks are used for printing on thermoplastic surface, then print quality is improved, but environmental harm increases
Solution Approach 1:
The primer layer acts as a mediator that enables aqueous inks to achieve print quality previously only attainable with UV or solvent inks. The metal salt in the primer precipitates the pigment from aqueous ink, creating stable, high-quality prints without environmental harm
Solution Approach 2:
The naturally bleeding tendency of aqueous ink on thermoplastic surfaces is converted into a benefit through the primer layer. The bleeding causes pigment precipitation and agglomeration, which actually improves ink fixation and prevents unwanted spreading, turning a harmful effect into a quality-enhancing mechanism
3Device complexity
If aqueous ink is printed directly on thermoplastic carrier, then printing process is simplified, but ink bleeding occurs resulting in poor print quality
Solution Approach 1:
The primer layer is applied in advance before the printing step, preparing the surface to receive and properly interact with the aqueous ink. This preliminary action prevents bleeding during printing while maintaining process simplicity, as the primer application is integrated into the existing production line
4Manufacturing precision
If primer comprising metal salt is applied before printing, then ink bleeding is prevented and print quality is improved, but process complexity increases
Solution Approach 1:
The primer application and printing operations are merged into a single integrated process flow. The primer layer is applied and then immediately printed upon in sequence, combining two steps into a unified production process that minimizes additional complexity while achieving high print quality
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
This approach allows for high-quality, environmentally friendly printing of decorative patterns on thermoplastic materials using aqueous inks, preventing ink bleeding and maintaining the bonding strength between layers during the assembly of building panels.
Implementation Method 1
applying a primer comprising at least one salt, preferably a metal salt, on a first surface of the carrier prior to printing the first print, wherein said salt precipitates or agglomerates the pigment of the ink composition
Data Source
Figure 1
Figure 2a~2d
Figure 3a~3c
AI summary
The present invention relates to a method of producing a building panel (1)such as a floor panel, comprising providing a carrier (3) comprising a thermoplastic material,applying a primer comprising at least one salt, preferably a metal salt,on a first surface of the carrier (3),printing by means of digital printing a first print (10) on said first surface of the carrier (3) with an aqueous pigment ink composition, and applying a protective layer (4) on the carrier (3) and applying the carrier (3) on a core (2) comprising a thermoplastic material, and pressing by applying heat and pressure the protective layer (4), the carrier (3) and the core (2) together to form a building panel (1).The present invention also relates to a method for forming a decorative substrate.