Decor Paper Printing Method Using Ink Receiving Layer

Solution Overview

Problem

Current methods for manufacturing decorative papers or foils for laminate boards face challenges with high production costs and limited flexibility, particularly in small batch production, due to the expense and time-consuming nature of rotogravure printing, and the lower production rate and higher ink costs associated with inkjet printing.

Innovation Solution

A method that combines multiple printed motifs using different printing techniques, such as analog and digital printing, with an ink receiving layer to enhance ink absorption and minimize color variation, allowing for increased decorative variability and cost reduction by optimizing ink usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If rotogravure printing is used for manufacturing décor paper, then high production rate is achieved, but preliminary engraving operation increases cost and time consumption

Engineering Contradiction:

Improveproduction rateVSAvoidpreliminary operation time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent divides the printing process into multiple independent printing units (first printing unit with first printing technique, second printing unit with second printing technique) that can operate simultaneously or sequentially without requiring preliminary engraving operations. This segmentation allows each unit to be configured for specific printing needs, eliminating the time-consuming engraving step while maintaining high production rates.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies preliminary action by providing an ink receiving layer on the substrate before the printing steps. This pre-treatment layer is specifically designed to optimize ink absorption and minimize color variation, preparing the substrate in advance to receive multiple printed motifs without requiring time-consuming adjustments during the printing process.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If inkjet printing is used for manufacturing décor paper, then flexibility and customization are improved, but production rate decreases and ink cost increases

Engineering Contradiction:

Improveproduction flexibilityVSAvoidproduction rate

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent merges multiple printing techniques (analog printing in the first printing unit and digital/inkjet printing in the second printing unit) into a single integrated printing system. This combination allows the system to leverage the high production rate of analog printing for base layers while utilizing the flexibility of digital printing for customized overlays, thereby achieving both high productivity and production flexibility simultaneously.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent applies local quality by using different printing techniques for different regions or layers of the printed motif. The first printing unit applies analog printing techniques suitable for大面积 uniform patterns, while the second printing unit applies digital printing techniques for detailed or customized areas, optimizing both production rate and flexibility in different zones of the décor paper.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If multiple printed motifs are combined to increase decorative variability, then décor quality improves, but ink consumption and color variation increase

Engineering Contradiction:

Improvedecorative variabilityVSAvoidink consumption

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The patent applies preliminary action by providing an ink receiving layer on the substrate before the printing steps. This pre-treatment layer is specifically designed to optimize ink absorption and minimize color variation, preparing the substrate in advance to receive multiple printed motifs without requiring time-consuming adjustments during the printing process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies local quality by using different printing techniques for different regions or layers of the printed motif. The first printing unit applies analog printing techniques suitable for大面积 uniform patterns, while the second printing unit applies digital printing techniques for detailed or customized areas, optimizing both production rate and flexibility in different zones of the décor paper.

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

This approach enhances the quality and variability of decorative papers or foils by combining motifs from different printing techniques, reducing ink consumption, and improving ink absorption, thereby making small batch production more economically viable.

Implementation Method 1

The ink receiving layer further provides the advantage of improving the ink absorption thereby minimizing the color variation caused by the combination of multiple printed motifs

Methodology Applied

Scientific EffectInk absorption: Absorption (physical)

Data Source

PatentUS20240001701A1A method for manufacturing a dÉcor paper or foil and a dÉcor paper or foil

Publication Date: 2024.01.04 INTERPRINT GMBH & CO KG

AI summary

A method for manufacturing a décor paper or foil may involve providing a paper layer or a foil. The paper layer or the foil may be provided with a first printed motif that is provided by a first printing technique. A second printed motif may be provided above the first printed motif. The second printed motif may be provided by a second printing technique. The paper layer or the foil may be provided with an ink receiver layer.