CPL Laminate Structuring for Deep Decor-Synchronous Textures
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Solution Overview
Problem
Existing methods for producing laminates in CPL presses struggle to create deep, decor-synchronous structures efficiently, leading to substandard quality and increased production costs due to the limitations of 3D printing and coating processes.
Innovation Solution
A method involving digital data processing to determine resin application based on decoration patterns, combined with a structuring agent in a CPL press, allowing for precise control of resin distribution and structure formation, enabling deep, decor-synchronous textures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If 3D printing is used to create deep structures, then structure depth can be achieved, but production time increases and productivity decreases
Solution Approach 1:
The surface structure is created on the decorative paper layer before the laminating process. The decorative paper layer is prepared with the desired surface structure (e.g., wood grain patterns, pores, or other textures) in advance, so that when the laminate is assembled and pressed, the structure is already in place and does not require time-consuming 3D printing during production.
2Shape
If coating processes are used to create structures, then surface effects can be achieved, but manufacturing complexity increases and costs rise
Solution Approach 1:
Instead of using complex coating processes to create surface structures, the patent uses a decorative paper layer that is printed or embossed with the desired surface pattern. This copies the desired surface structure directly onto the paper layer during the laminating process, eliminating the need for separate coating equipment and complex manufacturing steps.
3Ease of manufacture
If simple pore structures are used, then manufacturing is easier, but visual and tactile realism decreases
Solution Approach 1:
The patent applies different resin amounts to different areas of the decorative paper layer based on the surface structure requirements. Areas with deeper structures (such as wood pores or grain patterns) receive more resin, while flatter areas receive less resin. This parameter change in resin application enables the creation of deep, realistic structures without complicating the manufacturing process, as the resin is applied in the same laminating step using a structured carrier.
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 laminates with structure depths greater than 100 µm, enhancing visual and tactile realism while maintaining cost-effectiveness by integrating into existing manufacturing processes.
Implementation Method 1
applying at least one layer of resin to the printed decorative paper layer in case a. (i); or applying at least one layer of resin to the overlay paper layer in case a. (ii)
Implementation Method 2
Pressing the at least one kraft paper layer and the decorative paper layer printed with a decoration with the at least one resin layer using a structure provider in a CPL press
Data Source
Figure 1~2
AI summary
The invention relates to a method for producing a laminate (100), in particular a laminate in a CPL press with a structure synchronous to a decoration.