Wood Substrate Floor Tile Coating for Veneer Masking
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Solution Overview
Problem
The existing methods for manufacturing floor tiles with a wood-based substrate using digital printing are costly and complex due to the need for separate supports and layers, which can affect printing quality and increase production costs, while using smaller pieces of veneer to reduce costs results in a lower visual quality due to visible junctions.
Innovation Solution
A method involving a wood-based substrate with a core layer and upper veneer layer, where the substrate is coated with multiple layers including a hardener and filler, and digitally printed with UV inks, masking imperfections and junctions between veneer pieces to achieve a high-quality, cost-effective floor tile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single piece of veneer covers the core layer of the tile, then the visual quality is improved, but the production cost increases
Solution Approach 1:
A coating layer is applied over the veneer pieces to change the visual appearance by masking junctions and imperfections. The coating creates a uniform surface that hides the boundaries between multiple veneer pieces, making the tile appear as if it has a single continuous veneer surface, thus resolving the contradiction between using multiple pieces for cost savings and maintaining visual quality.
2Quantity of substance
If several pieces of veneer are used to cover the core layer, then the production cost is decreased, but the visual quality deteriorates due to visible junctions
Solution Approach 1:
The coating layer applied over the veneer pieces changes the visual appearance by creating a uniform surface that masks the junctions between pieces. This allows multiple cost-effective veneer pieces to be used while maintaining the visual quality equivalent to a single continuous piece.
3Manufacturing precision
If a separate support is used for printing the décor, then the printing quality is improved, but the process complexity and cost increase
Solution Approach 1:
The basic layer and the décor printing are merged into a single integrated process. The décor is printed directly onto the basic layer that is already applied to the substrate, eliminating the need for a separate printing support. This reduces process complexity and cost while maintaining printing quality, as the ink is applied directly to the adherent basic layer without requiring additional intermediate supports.
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 method produces floor tiles that provide a better visual quality at a competitive cost by masking veneer imperfections and junctions, using less veneer material while maintaining durability and offering a natural laminate design.
Implementation Method 1
masking imperfections and junctions between veneer pieces
Implementation Method 2
digitally printed with UV inks
Data Source
AI summary
A method for the manufacture of a floor tile (1), comprising at least the following successive steps: - obtaining a substrate (2) having at least a wood based upper layer (4); - coating the substrate (2), wherein coating the substrate (2) comprises applying at least a first layer of coating (15) on the upper surface (13), curing the first layer of coating (15) using UV rays, applying a second layer of coating (17) on the first layer of coating (15), and curing the second layer of coating (17) using UV rays, wherein the first layer of coating (15) contains a hardener and the second layer of coating (17) contains a filler; - applying a primer layer (7) on the coated substrate; - digitally printing a décor (9) on the primer layer (7); and - applying a top coat (11) on the décor (9).