UV-Curable Decorative Board Coating for Smoothness
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Solution Overview
Problem
Conventional decorative boards with printed paper as a decorative layer suffer from poor smoothness and insufficient visual quality due to the uneven texture of the paper, and existing solutions with coating materials do not provide adequate visual quality.
Innovation Solution
A decorative board comprising a primer layer, a concealing layer, and a topcoat layer containing ultraviolet-curable resin, arranged in order on a base material, with a method involving a stretching process, irradiation process, and separation process to achieve excellent smoothness and visual quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If printed paper is used as the decorative layer, then the aesthetic design property is improved, but the smoothness of the decorative board deteriorates due to uneven texture pickup
Solution Approach 1:
The patent removes the printed paper layer from the decorative board structure and replaces it with a coating material layer that can be applied directly to the base material. This extraction eliminates the source of texture unevenness while maintaining the ability to achieve smooth surfaces through proper coating application techniques.
Solution Approach 2:
The patent changes the physical and chemical parameters of the decorative layer by using coating materials with specific viscosity, drying characteristics, and composition ratios. By adjusting these parameters, the coating can be applied smoothly without picking up texture from paper, while still providing aesthetic design properties through color and finish options.
2Manufacturing precision
If coating material is used to form the decorative layer, then the smoothness is improved, but the visual quality becomes insufficient
Solution Approach 1:
The patent employs composite coating materials that combine multiple components including binders, pigments, fillers, and additives in specific ratios. This composite structure allows the coating to achieve both smooth application and high visual quality, as different components contribute to different properties: some ensure smooth flow and leveling, while others provide color depth, gloss, and aesthetic appeal.
3Shape
If multiple layers are added to improve visual quality, then the aesthetic property is enhanced, but the manufacturing complexity increases
Solution Approach 1:
The patent combines multiple functional components into a single integrated coating material formulation. Instead of applying separate layers for different functions (adhesion, color, gloss, protection), the invention merges these functions into one coating material that can be applied in a single operation, thereby reducing manufacturing complexity while maintaining visual 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
The solution results in a decorative board with enhanced smoothness and fair visual quality, improved fire resistance, and various finish options, while maintaining the base material's strength and light resistance.
Implementation Method 1
a topcoat layer containing ultraviolet-curable resin arranged on a base material in this order
Data Source
AI summary
A decorative board in the present disclosure includes a primer layer, a concealing layer, a colorant layer and a topcoat layer containing ultraviolet-curable resin on a base material in this order. A method for manufacturing the decorative board in the present disclosure includes a stretching process, an irradiation process, and a separation process. The stretching process includes forming the primer layer, the concealing layer, and the colorant layer on the base material in this order; applying a ultraviolet-curable coating material containing ultraviolet-curable resin; placing a plastic film on the applied ultraviolet-curable coating material, placing a roller on the plastic film, and stretching the ultraviolet-curable coating material by rolling the roller. The irradiation process includes forming the topcoat layer by hardening the ultraviolet-curable coating material by ultraviolet ray irradiation. The separation process includes separating the plastic film after the irradiation.