Decorative Laminate Inkjet Printing for Adhesion and Grain Alignment

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Solution Overview

Problem

The existing manufacturing processes for decorative laminates using inkjet technology face challenges with adhesion issues between acrylate ink layers and melamine resin, particularly at high ink coverages, and difficulties in aligning wood grain patterns due to dimensional instability during thermosetting resin impregnation.

Innovation Solution

A method involving the use of aqueous pigmented inkjet inks with an inorganic pigment and polymeric binder in a specific ratio, applied to an ink acceptance layer on a fully impregnated base paper, allowing for improved adhesion and alignment of wood grain patterns, and enabling in-house printing that eliminates the need for intermediate decor printers and warehouses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If acrylate inkjet inks are used for printing decorative patterns, then image quality is improved, but adhesion problems occur between the ink layer and melamine resin protective layer

Engineering Contradiction:

Improveimage qualityVSAvoidadhesion

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent applies a primer layer containing silane-modified polyurethane resin before applying the acrylate inkjet ink. This preliminary action creates a compatible interface between the ink and the melamine resin, allowing the ink to properly adhere to the protective layer during heat pressing without compromising image quality.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The silane-modified polyurethane resin acts as an intermediary layer between the acrylate inkjet ink and the melamine resin. This intermediary material has compatibility characteristics with both substances, enabling proper adhesion and preventing the delamination that would occur with direct contact between acrylate ink and melamine resin.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If thermosetting resin is applied for impregnation, then wear resistance is improved, but dimensional instability occurs during impregnation causing misalignment of wood grain patterns

Engineering Contradiction:

Improvewear resistanceVSAvoidalignment of wood grain patterns

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent pre-prints the wood grain pattern and performs preliminary drying to stabilize the paper dimensions before applying the thermosetting resin for impregnation. This preliminary stabilization prevents dimensional changes during resin application that would cause misalignment of the wood grain pattern.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies different treatments to different layers: the paper substrate receives thermosetting resin impregnation for wear resistance, while the printed decorative layer is protected by the primer system that maintains its dimensional stability and pattern alignment during the impregnation process.

Inventive Principle:

Principle #3Local quality

3Reliability

If ink acceptance layer with inorganic pigment and polymeric binder is used, then adhesion is improved, but manufacturing complexity increases

Engineering Contradiction:

ImproveadhesionVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The silane-modified polyurethane resin serves multiple functions simultaneously: it acts as a primer to improve adhesion, provides a compatible interface for the acrylate ink, and maintains dimensional stability during subsequent processing. This multi-functionality reduces the need for separate specialized layers, simplifying the overall manufacturing process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution achieves excellent image quality and adhesion, simplifies the manufacturing process, reduces storage needs, and allows for rapid design changes and cost-efficient short print runs, minimizing paper loss and financial penalties.

Implementation Method 1

printing a colour pattern by jetting droplets having a volume of 1 to 30 pL of one or more aqueous pigmented inkjet inks onto the dried ink acceptance layer

Methodology Applied

Scientific EffectInkjet printing:

Implementation Method 2

the water vapour produced during the polycondensation of the melamine cannot penetrate through the polymerized acrylate ink layer

Methodology Applied

Scientific EffectPolycondensation:

Implementation Method 3

the water vapour produced during the polycondensation of the melamine

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 4

An ink acceptance layer is printed in a first step by jetting droplets having a volume of 1 to 200 nL onto a paper substrate

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentUS10112426B2Manufacturing methods of decorative laminates by inkjet

Publication Date: 2018.10.30 AGFA NV

AI summary

A manufacturing method of decorative laminates includes the steps of: a) printing an ink acceptance layer by jetting droplets having a volume of 1 to 200 nL onto a paper substrate; b) forming a decorative layer by jetting ink droplets having a volume of up to 30 pL of one or more aqueous pigmented inkjet inks onto the dried ink acceptance layer; and c) heat pressing the decorative layer into a decorative laminate; wherein the ink acceptance layer contains an inorganic pigment P and a polymeric binder B in a weight ratio P/B larger than 1.5.