Decorative Panel Lamination With Sequential Resin Impregnation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Inkjet printed decorative papers in laminate panels face issues with paper splitting due to insufficient bonding of fibers, as the décor paper fibers are not fully saturated and covered with thermosetting resin.
Innovation Solution
A method involving multiple impregnation steps with thermosetting resins, where a first resin impregnates less than 50% of the absorption capacity, followed by drying, and a second resin fully saturates the paper, improving resin absorption and reducing the risk of splitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single impregnation step with thermosetting resin is used, then the manufacturing process is simple and fast, but the decorative paper fibers are not fully saturated with resin causing paper splitting
Solution Approach 1:
The impregnation process is divided into multiple sequential steps: first impregnation with initial resin, drying step, second impregnation with additional resin, and final drying. This segmentation allows complete saturation of decorative paper fibers without requiring complex single-step equipment, resolving the contradiction between lamination quality and process complexity.
Solution Approach 2:
The first impregnation and drying step prepares the decorative paper by partially saturating fibers and removing moisture, creating optimal conditions for the second impregnation. This preliminary action ensures that the second resin application achieves complete fiber saturation, improving lamination quality while maintaining a manageable multi-step process.
2Reliability
If multiple impregnation steps are used to fully saturate the decorative paper, then paper splitting is reduced, but the manufacturing time and process complexity increase
Solution Approach 1:
The impregnation process uses periodic action with distinct phases: impregnation, drying, impregnation, drying. Each phase allows the previous phase to complete fully before initiating the next, ensuring complete resin saturation and fiber bonding while maintaining a systematic production rhythm that balances reliability with manufacturing efficiency.
Solution Approach 2:
The process changes physical parameters between steps: moisture content is reduced during drying phases, resin concentration and saturation level are increased in sequential impregnation steps. These parameter changes ensure complete fiber saturation and strong bonding while allowing each step to be optimized independently for time and quality.
3Adaptability or versatility
If analog printing is used for decorative paper, then printing cost is low, but flexibility is restricted and large minimal order quantities are required
Solution Approach 1:
The patent replaces analog mechanical printing systems with digital printing technology. This substitution eliminates the need for physical printing plates and extensive setup time, allowing flexible production of small quantities with different decor patterns without proportionally increasing cost, thus resolving the contradiction between adaptability and minimal order quantity.
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 enhances the lamination process by ensuring complete resin absorption, thereby reducing paper splitting and improving the quality of laminate panels.
Implementation Method 1
the décor paper fibers are not fully saturated and covered with thermosetting resin
Implementation Method 2
the press treatment results in a mutual connection or adherence of the decorative paper, the substrate and the protective layer, as well as in a hardening of the resin present in the stack
Data Source
Figure 1~4
Figure 3~5
AI summary
A method for manufacturing a laminate assembly (1) that comprises the steps of providing a decorative paper (7), impregnating said decorative paper (7) with a first thermosetting resin (12), laminate said resin provided decorative paper (7) on a substrate (4), with the characteristic that the method comprises the step of impregnating said decorative paper (7) with a second thermosetting resin (13) before being laminated.