UV Curable Inkjet Decorative Panels for Water Resistance
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Solution Overview
Problem
Existing decorative surfaces made from wood and paper-based materials have limited water resistance, making them unsuitable for bathrooms and kitchens, and current solutions require experienced workers for installation and involve high costs and waste due to the need for large flooring rolls and minimum purchasing quantities.
Innovation Solution
A method using specific pigmented UV curable inkjet inks for manufacturing decorative panels, which involves inkjet printing on thermoplastic foils, UV curing, and heat pressing to create a durable and water-resistant laminate with improved image quality and adhesion, allowing for in-house production and customization without the need for large stock rolls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If water-based or solvent-based inks are used for printing on thermoplastic foil, then the printing process is simple, but image quality deteriorates due to bleeding and the ink is not suitable for water-resistant applications
Solution Approach 1:
The patent changes the fundamental parameter of ink chemistry from water-based/solvent-based to UV-curable formulation. This enables the ink to be printed at low viscosity for good image quality, then cured to achieve water resistance and prevent bleeding, resolving both the simplicity and quality requirements
Solution Approach 2:
The patent creates a composite system combining UV-curable ink formulation with thermoplastic foil substrate. The ink contains polymerizable compounds that form a cross-linked network after UV curing, creating a composite material structure that provides both printability and water resistance
2Reliability
If large flooring rolls are used for wall-to-wall application, then water resistance is achieved, but installation complexity increases requiring experienced workers and furniture removal
Solution Approach 1:
The patent segments the large flooring roll into smaller, manageable decorative panels that can be individually handled and installed. Each panel maintains the water-resistant properties while being easy to install with interlocking structures, eliminating the need for complex wall-to-wall roll application
Solution Approach 2:
The patent introduces an intermediary printing and lamination process that applies decorative patterns and protective layers to individual panels before installation. This intermediary step creates pre-finished panels that combine water resistance with ease of installation
3Ease of manufacture
If decorative rolls are ordered in minimum purchasing quantities in advance, then production costs are reduced, but adaptability to market trends deteriorates and waste increases
Solution Approach 1:
The patent applies preliminary UV curing to the inkjet-printed decorative patterns on panels before final assembly. This preliminary action allows panels to be produced on-demand with customized designs while maintaining cost efficiency through standardized processing steps, enabling rapid response to market trends without minimum order quantities
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 method enables the production of decorative panels with excellent image quality and adhesion, reduced waste, and faster market responsiveness, allowing for customized products with improved water resistance and simplified installation processes.
Implementation Method 1
inkjet printing and UV curing an image on a first thermoplastic foil using a pigmented UV curable inkjet ink
Implementation Method 2
heat pressing the thermoplastic foils into a decorative laminate
Data Source
Figure 1~3
AI summary
A method for manufacturing decorative surfaces including the steps of: a) inkjet printing (19) an image on a first thermoplastic foil (12) using a pigmented UV curable inkjet ink; b) applying a second thermoplastic foil (12) on the inkjet printed image; and c) heat pressing (20) the first and second thermoplastic foils into a decorative laminate; wherein the pigmented UV curable inkjet ink contains a polymerizable composition having 35 to 70 wt% of monofunctional polymerizable compounds and 30 to 65 wt% of polyfunctional polymerizable compounds, wherein the weight percentage wt% is based on the total weight of the polymerizable composition; and wherein at least one of the first and second thermoplastic foils is a transparent foil.