Decorative laminate made of resin impregnated paper and its production
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Solution Overview
Problem
Conventional decorative laminates produced using continuously operating presses have a uniform structure, which limits the achievement of desired surface effects, particularly when the decorative side is made of a plain or white layer, and do not offer enhanced abrasion resistance or optical variations.
Innovation Solution
A method involving a structuring belt, structuring paper, or press plate with at least two elongated, adjacent surface areas of different textures, where the more heavily textured area is narrower than the less heavily textured area, and a linear structuring element creates a notch to separate these areas, resulting in a laminate with enhanced visual and haptic effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a uniform structuring surface is used in continuously operating presses, then the production process is simple and efficient, but the surface effects are limited and lack visual appeal
Solution Approach 1:
The structuring surface is divided into multiple distinct zones with different texturing characteristics. The press plate or structuring belt includes at least two different structuring zones, each creating different surface effects (e.g., matte, glossy, textured) on different portions of the laminate simultaneously during continuous production.
Solution Approach 2:
Different regions of the structuring surface are assigned different texturing properties to achieve local surface quality variations. Each zone is optimized for specific visual or haptic effects, allowing the laminate to display multiple surface characteristics in a single production run without changing the structuring tool.
2Adaptability or versatility
If heavily textured areas are made wider to enhance visual effect, then the decorative impact is improved, but the cleaning difficulty increases and maintenance becomes more complex
Solution Approach 1:
The laminate surface is designed with locally differentiated texturing where heavily textured decorative zones are strategically positioned and dimensioned. The textured areas provide enhanced visual appeal while their specific geometry and positioning allow for practical cleaning access, balancing aesthetic requirements with maintenance considerations.
3Adaptability or versatility
If multiple different structuring surfaces are used to achieve varied surface effects, then the decorative possibilities are expanded, but the production time and process complexity increase
Solution Approach 1:
Multiple structuring functions are integrated into a single press plate or structuring belt by dividing the contact surface into distinct zones. Each zone applies a different texturing pattern simultaneously as the laminate passes through the press, eliminating the need for multiple pressing operations or tool changes while maintaining high production speed.
Solution Approach 2:
The patent combines multiple structuring capabilities into one integrated press plate or structuring belt assembly. Different texturing patterns, depths, and types are merged into a single tool that contacts the laminate simultaneously across different zones, achieving varied surface effects in one continuous pressing operation without compromising productivity.
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
The method expands the possibilities for achieving desired surface effects by creating decorative laminates with distinct textured areas, providing a more visually appealing and haptic experience while maintaining ease of cleaning, and allowing for various applications with minimal waste.
Implementation Method 1
The application of heat and pressure causes the resins to flow and then cure. The cross-linking of the resins, reinforced by the cellulose fibers of the paper, creates a very dense material with a closed surface.
Implementation Method 2
HPL laminates are usually produced in multi-daylight presses with a pressure of between 50 and 90 bar and temperatures of over 120°C.
Implementation Method 3
HPL laminates are usually produced in multi-daylight presses with a pressure of between 50 and 90 bar and temperatures of over 120°C.
Implementation Method 4
the surface of the laminate being textured by means of the structuring belt, structuring paper or press plate
Data Source
Figure 1~3
AI summary
The invention relates to a method for producing a decorative laminate from resin-impregnated paper layers using a press, in which the surface of the laminate is textured using a structuring belt, structuring paper or press plate. The invention also relates to a decorative laminate made of resin-impregnated paper layers, in particular for covering a door panel, the surface of which is textured. The invention is based on the object of creating such a laminate which is inexpensive and of comparatively high quality and with which the possibilities of achieving desired surface effects are expanded. The method according to the invention is characterized in that the structuring belt, structuring paper or press plate used for texturing has at least two elongated surface areas (2, 3; 2', 3; 2", 3) lying next to each other with different degrees of texturing, the more heavily textured surface area having a width or average width of at least 10 cm, and wherein the more textured area (2, 2', 2") is narrower than the less highly textured area (3). The invention thus provides a decorative laminate (1, 1', 1") made of resin-impregnated paper layers, the surface of which has at least two elongated, adjacent surface areas (2, 3; 2', 3; 2", 3) of different thicknesses Has texturing, wherein the more textured area (2, 2', 2") has a width or average width of at least 10 cm, and wherein the more textured area is narrower than the less heavily textured area (3, 3'). The The laminate (1, 1′, 1″) according to the invention can be used in particular for the coating of doors, preferably interior doors.