Decorative Laminate Metallic Lacquer Adhesion
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Solution Overview
Problem
Decorative laminates based on decorative paper struggle to achieve both the required mechanical and chemical resistances and a visually appealing metallic surface impression, especially for heavily used surfaces like horizontal worktops, due to issues with paint adhesion and the milky appearance caused by corundum overlays.
Innovation Solution
A decorative laminate comprising a first thermoplastic polymer film and a second transparent thermoplastic polymer film connected via a lacquer layer containing metal effect pigments, which provides enhanced mechanical and chemical resistance while maintaining a close visual impression to a real metallic surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a corundum-containing overlay is applied to decorative paper to improve mechanical resistance, then mechanical strength is improved, but the optical appearance deteriorates due to milky appearance
Solution Approach 1:
The patent changes the material parameters from traditional decorative paper with corundum overlay to thermoplastic polymer films. The first thermoplastic polymer film provides the base structure, while the second transparent thermoplastic polymer film maintains optical clarity. The lacquer layer with metallic effect pigments is applied between these films to achieve both mechanical strength and metallic optical appearance without the milky effect caused by corundum.
2Reliability
If conventional paints are applied to metallic surfaces to improve chemical resistance, then chemical resistance is improved, but paint adhesion deteriorates
Solution Approach 1:
The patent uses a composite structure consisting of thermoplastic polymer films combined with a lacquer layer containing metallic effect pigments. This composite material system provides both the desired chemical resistance and strong adhesion, eliminating the problem of paint peeling from metallic surfaces while maintaining the metallic optical appearance.
3Ease of manufacture
If decorative paper is used as base material to reduce costs, then manufacturing cost is improved, but mechanical and chemical resistance deteriorates for heavily stressed surfaces
Solution Approach 1:
The patent changes the base material from decorative paper to thermoplastic polymer films. This parameter change provides significantly improved mechanical strength and chemical resistance suitable for heavily stressed surfaces like horizontal worktops, while still maintaining cost-effectiveness compared to solid metal components. The thermoplastic materials offer better durability without requiring expensive metal substrates.
Data Source
Figure 1~2
AI summary
The invention relates to a decorative laminate comprising a first thermoplastic polymer film and a second transparent thermoplastic polymer film, characterized in that the first and the second thermoplastic polymer film are bonded together by a lacquer layer, wherein the lacquer layer contains metallic effect pigments. The invention further relates to a method for producing a decorative laminate comprising the following steps: a) providing a first thermoplastic polymer film, b) coating one side of the first thermoplastic polymer film with a lacquer, wherein the lacquer contains metallic effect pigments, c) applying a second transparent thermoplastic polymer film to the lacquer, d) completely curing the resulting decorative laminate.Finally, the invention relates to the use of the decorative laminate according to the invention for the production of compact panels, edge banding, window profiles, doors, facade panels, furniture or floors.