3D Structural Surfaces via Ink Swelling Agents
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Solution Overview
Problem
Existing methods for producing three-dimensional structural surfaces on wood-based panels require costly and time-consuming preparation of press plates corresponding to individual patterns, and precise positioning of impregnated decor paper, making it inefficient and costly to produce synchronous surfaces.
Innovation Solution
A method involving the application of a mixture containing printing ink and microencapsulated swelling agents to the decor paper during printing, which expands during the pressing process to create a coded three-dimensional structure, allowing for the production of synchronous surfaces without the need for specialized press plates or precise positioning systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional methods are used to produce three-dimensional synchronous surfaces, then the surface structure precisely reflects the printed pattern, but costly and time-consuming preparation of specialized press plates and precise positioning systems are required
Solution Approach 1:
The swelling agent is applied to the decor paper during the printing stage, before the pressing process. This preliminary application allows the three-dimensional structure to be pre-defined on the paper itself, eliminating the need for complex press plate preparations and positioning systems during the pressing stage.
Solution Approach 2:
The pattern information is copied from the printing stage to the swelling agent application stage. The swelling agent is applied in the form of a printing ink mixture, so the pattern that defines the three-dimensional structure is already present on the paper before pressing, replacing the need for specialized press plates.
2Manufacturing precision
If specialized press plates are used for each pattern, then synchronous surfaces are achieved, but production costs and time increase significantly
Solution Approach 1:
The structure-defining swelling agent is applied during printing, before the pressing process. This eliminates the need to prepare and change specialized press plates for different patterns, allowing continuous production with standard press plates and significantly improving productivity.
Solution Approach 2:
The state of the swelling agent changes from inactive (at printing and impregnation temperatures) to active (at pressing temperatures). This parameter change allows the structure to be defined during printing and then activated during pressing, eliminating the need for pattern-specific press plates and enabling high-speed production.
3Manufacturing precision
If precise positioning systems are used to match impregnate pattern with press plate, then synchronous surfaces are produced, but equipment complexity and cost increase
Solution Approach 1:
The swelling agent is applied during the printing stage, where the pattern is already precisely defined on the paper. This preliminary structuring eliminates the need for complex positioning systems during pressing, as the structure is already aligned with the desired pattern before the paper enters the press.
Solution Approach 2:
The pattern information is copied directly onto the paper through the printing process with the swelling agent mixture. This creates a self-aligned structure that requires no additional positioning during pressing, replacing complex positioning systems with a simple printing-based pattern transfer.
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
Enables the production of three-dimensional synchronous surfaces independent of the press plate surface, reducing production costs and time by defining the structure during the printing stage with a swelling agent, and achieving precise matching of the final surface to the printed pattern without the need for specialized equipment.
Implementation Method 1
a mixture is applied to the decor paper, consisting of printing ink and a swelling agent in the form of microspheres, being encapsulated gas bubbles of sizes ranging from 2μm to 180μm, increasing its volume under the influence of rising temperature
Data Source
AI summary
The invention relates to a method of producing three-dimensional structural surfaces based on synthetic resin-impregnated materials applied to the surface, in particular of wood-based panels. The method is characterized in that before the impregnation, at the stage of pattern printing, a mixture is applied to the decor paper, consisting of printing ink, whether with pigment or not, and a swelling agent in the form of microspheres, being encapsulated gas bubbles of sizes ranging from 2pm to 180pm, increasing its volume under the influence of rising temperature, wherein the mixture of the ink and the swelling agent contains from 0.3% to 45% by weight of the swelling agent, and after exiting the printing press and after the impregnation, the decor paper with the formed final pattern with a coded three-dimensional structure is pressed onto the surface, in particular of a wood-based panel, using a heated press plate with any working surface.