UV-Curable Multilayer Tile Structure with Organosilicon Protective Layer
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Solution Overview
Problem
Existing methods for producing patterned tiles with multilayer structures face challenges such as narrow pigment color reproduction, high production costs due to high-temperature calcination, and the need for large-scale equipment, along with inadequate scratch resistance from organic resin layers.
Innovation Solution
A process involving the formation of a multilayer structure with a substrate layer, an image layer created using a UV-curable composition containing colored pigments and radically polymerizable compounds, and a protective layer formed through a condensation reaction of an organosilicon compound, which eliminates the need for high-temperature calcination and uses inkjet printing or screen printing for application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If high-temperature calcination is used to form the image layer, then the pigment color reproduction and design flexibility are improved, but the production cost increases and large-scale equipment is required
Solution Approach 1:
The patent changes the temperature parameter from high-temperature calcination (typically above 800°C) to low-temperature curing (below 200°C) by switching from ceramic-based materials to UV-curable organic resin-based materials. This parameter change enables the use of conventional printing equipment instead of specialized high-temperature furnaces, reducing production costs while maintaining design flexibility and color reproduction capabilities through the use of various pigments and dyes compatible with UV curing.
2Adaptability or versatility
If high-temperature calcination is used to form the image layer, then the pigment color reproduction and design flexibility are improved, but large-scale equipment is necessary for production
Solution Approach 1:
The patent replaces the thermal field (high-temperature calcination) with a photochemical field (UV irradiation). This substitution allows the use of UV lamps and conventional printing equipment instead of large-scale high-temperature furnaces, significantly reducing equipment scale and complexity while maintaining design flexibility through the ability to use various pigments and dyes that can be cured by UV light.
3Ease of manufacture
If a UV-curable composition is used to form the image layer, then production cost is reduced and design flexibility is improved, but surface hardness and scratch resistance are insufficient
Solution Approach 1:
The patent creates a composite protective layer by combining UV-curable organic resin with inorganic particles (such as silica, alumina, or titania). The organic resin matrix provides adhesion and flexibility, while the dispersed inorganic particles contribute hardness and scratch resistance. This composite structure achieves a balance between the low production cost and design flexibility of UV curing and the surface hardness requirements, without requiring high-temperature calcination.
4Ease of manufacture
If a UV-curable composition is used to form the image layer, then production cost is reduced, but long-term durability and impact resistance are compromised
Solution Approach 1:
The patent enhances the durability and impact resistance of the UV-curable image layer by incorporating inorganic particles (such as silica, alumina, or titania) into the organic resin matrix. These inorganic particles act as reinforcement, improving mechanical strength, scratch resistance, and long-term durability. The composite structure maintains the low production cost and design flexibility of UV curing while achieving the required reliability for practical applications.
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 process results in a multilayer structure with improved surface hardness, impact resistance, and durability, while reducing production costs and enabling a wider color gamut without discoloration, and enhances adhesion between layers.
Implementation Method 1
forming, above a substrate layer (Layer 1), an image layer (Layer 2) by applying a UV-curable composition comprising a colored pigment, a radically polymerizable compound comprising a (meth)acryloyl group-containing silane coupling agent and/or a phosphoric acid ester group-containing (meth)acrylate compound and a radical polymerization initiator by means of inkjet printing or screen printing and subsequently radically polymerizing the applied composition by means of UV exposure
Implementation Method 2
forming, above Layer 2, a protective layer (Layer 3) by applying a composition comprising an organosilicon compound and using a condensation reaction of the organosilicon compound
Data Source
AI summary
The object of the present invention is to provide a multilayer structure that does not require calcining at high temperature and large-scale equipment for production, that has low production cost and, furthermore, that has performance characteristics with respect to tiles such as for example surface hardness and excellent impact resistance and durability (surface hardness and impact resistance being unimpaired for a long period of time and there being no discoloration). Moreover, there can be provided a process for producing the multilayer structure and a composition set for producing the multilayer structure. Disclosed is a multilayer structure comprising, in sequence, (Layer 1) a substrate layer, (Layer 2) an image layer containing a colored pigment, and (Layer 3) a protective layer formed by a condensation reaction of an organosilicon compound.