UV-Curable LVT Surface Coating for Wear and Antimicrobial Durability
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Solution Overview
Problem
Existing UV curable surface coatings on luxury vinyl tiles (LVT) are prone to wear-through due to brittleness and high cost of antimicrobial additives, limiting their durability and effectiveness in commercial and industrial environments.
Innovation Solution
A two-coat UV curable surface coating system is applied, where the first coat is cured at lower energy and the second coat is cured at higher energy to enhance durability and antimicrobial efficacy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single thick layer of UV curable coating is applied to improve wear resistance, then the coating thickness increases, but the coating becomes brittle and prone to wear-through
Solution Approach 1:
The patent divides the coating system into multiple distinct layers (first UV curable coating layer and second UV curable coating layer) with different compositions and curing requirements. This segmentation allows each layer to be optimized for specific functions - the first layer provides base protection while the second layer enhances wear resistance, collectively achieving superior durability without the brittleness of a single thick coating.
Solution Approach 2:
The patent employs composite material structures by combining different UV curable coating formulations with distinct compositions. The first coating and second coating have different resin systems, crosslink densities, and physical properties, creating a composite coating system that leverages the advantages of each material to achieve both flexibility and wear resistance.
2Reliability
If high concentration of antimicrobial additives is added to UV curable coating to improve antimicrobial efficacy, then the antimicrobial performance improves, but the cost increases significantly
Solution Approach 1:
The patent optimizes the concentration parameters of antimicrobial additives by incorporating them into specific UV curable coating formulations at carefully controlled levels. By adjusting the additive concentration within optimal ranges and utilizing the synergistic effects of different coating layers, the system achieves effective antimicrobial protection while minimizing material costs.
Solution Approach 2:
The UV curable coating system provides self-sustaining antimicrobial protection through its formulation design. The coating layers are engineered to maintain effective antimicrobial activity throughout their service life without requiring additional applications or maintenance, delivering long-term protection that justifies the initial investment.
3Duration of action of stationary object
If thick application of UV curable coating is made to extend service life, then the coating thickness increases, but the brittleness increases and wear-through occurs earlier
Solution Approach 1:
The patent segments the coating into multiple layers with different thicknesses and compositions. The first coating layer provides a flexible base layer that adheres well to the substrate, while the second coating layer provides enhanced protection. This segmentation maintains flexibility while achieving the desired total thickness for extended service life.
Solution Approach 2:
Different regions of the coating system are designed with different properties - the first coating layer has specific composition and curing characteristics optimized for adhesion and flexibility, while the second coating layer has different properties optimized for wear resistance and durability. This local optimization ensures both flexibility and extended service life.
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 system provides improved wearability, scratch resistance, and long-term antimicrobial protection, extending the service life of LVT surfaces while reducing costs.
Implementation Method 1
an oligomer, a monomer, a photoinitiator
Data Source
AI summary
A surface covering is provided and generally includes a laminated panel, an ultra-violet (UV) and a second coating. The curable surface coating is applied to the laminated panel and includes a first coating. The second coating includes a composition distinctive of the first coating and is cured at a lower energy than the second coating. The second coating is cured at a higher energy to cure both the first coating and the second coating.