Wood-Based Surface Coating with UV-Cured Layers

Solution Overview

Problem

Existing surface coverings with a wood-based substrate struggle to combine low gloss with improved wear resistance and cleaning properties, often requiring a compromise between these aesthetic and technical properties.

Innovation Solution

A surface covering comprising a wood-based substrate, a radiation-curable surface coating layer formed by irradiating a UV light-sensitive coating agent with UV light of specific wavelengths, and a filler coating layer located between the substrate and the surface coating layer, which enhances the substrate's surface properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a surface coating layer with low gloss value is used to keep the natural aspect of wood, then aesthetic properties are improved, but wear resistance and cleaning ability deteriorate

Engineering Contradiction:

Improvegloss valueVSAvoidwear resistance

Core Design Contradiction:

Illumination intensityVSReliability

Solution Approach 1:

The coating system is divided into two distinct layers: a filler coating layer (first layer) that provides wear resistance and surface smoothing, and a surface coating layer (second layer) that provides low gloss aesthetic appearance. This segmentation allows each layer to optimize its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the coating system have different properties: the filler coating layer has high crosslinking density and smooth surface for durability, while the surface coating layer has low gloss for aesthetics. Each layer is specifically designed with local qualities suited to its function.

Inventive Principle:

Principle #3Local quality

2Illumination intensity

If a surface coating layer with low gloss value is used to keep the natural aspect of wood, then aesthetic properties are improved, but cleaning ability deteriorates

Engineering Contradiction:

Improvegloss valueVSAvoidcleaning ability

Core Design Contradiction:

Illumination intensityVSEase of operation

Solution Approach 1:

The coating system is divided into two distinct layers: a filler coating layer (first layer) that provides wear resistance and surface smoothing, and a surface coating layer (second layer) that provides low gloss aesthetic appearance. This segmentation allows each layer to optimize its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the coating system have different properties: the filler coating layer has high crosslinking density and smooth surface for durability, while the surface coating layer has low gloss for aesthetics. Each layer is specifically designed with local qualities suited to its function.

Inventive Principle:

Principle #3Local quality

3Reliability

If the coating thickness is increased to improve wear resistance, then technical properties are improved, but gloss value increases and natural wood aspect is lost

Engineering Contradiction:

Improvewear resistanceVSAvoidgloss value

Core Design Contradiction:

ReliabilityVSIllumination intensity

Solution Approach 1:

The coating system is divided into two distinct layers: a filler coating layer (first layer) that provides wear resistance and surface smoothing, and a surface coating layer (second layer) that provides low gloss aesthetic appearance. This segmentation allows each layer to optimize its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the coating system have different properties: the filler coating layer has high crosslinking density and smooth surface for durability, while the surface coating layer has low gloss for aesthetics. Each layer is specifically designed with local qualities suited to its function.

Inventive Principle:

Principle #3Local 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 achieves a surface covering with low gloss, improved wear resistance, and enhanced cleaning properties without compromising coating thickness, thereby addressing the limitations of existing technologies.

Implementation Method 1

a surface coating layer, said surface coating layer being obtained by the irradiation of a radiation-curable coating agent with UV light having a wavelength comprised from 120 nm to 230 nm

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Implementation Method 2

the irradiation being optionally followed by the curing of said coating by means of actinic radiation

Methodology Applied

Scientific EffectPhoto curing: Photopolymerisation

Data Source

PatentUS12330188B2Surface covering and method for the manufacture thereof

Publication Date: 2025.06.17 TARKETT GDL

AI summary

Disclosed is a surface covering including: a wood-based substrate; a surface coating layer, the surface coating layer being obtained by the irradiation of a radiation-curable coating agent with UV light having a wavelength included from 120 nm to 230 nm; and a filler coating layer, the filler coating layer being located between the wood-based substrate and the surface coating layer. Also disclosed is a method for the manufacture of such a surface covering.