Decorative Panel Lamination Using Staged Resin Saturation
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Solution Overview
Problem
Traditional analog printing methods for decorative panels result in high minimal order quantities and limited flexibility, while digital printing on laminate panels leads to paper splitting issues due to insufficient bonding of paper fibers with thermosetting resin.
Innovation Solution
A method involving multiple impregnation steps with thermosetting resins, where a first resin satisfies less than 50% of the decorative paper's absorption capacity, followed by drying, and a second resin fully saturates it, improving lamination and reducing paper splitting risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If digital printing is used on laminate panels, then flexibility in decorative patterns is improved, but paper splitting occurs due to insufficient bonding of paper fibers with thermosetting resin
Solution Approach 1:
The patent divides the resin impregnation process into multiple sequential steps: a first impregnation step with a first thermosetting resin, a drying step, and a second impregnation step with a second thermosetting resin. This segmentation allows each resin to perform a specific function - the first resin provides initial bonding and the second resin completes the saturation, together preventing paper splitting while maintaining the flexibility benefits of digital printing
Solution Approach 2:
The first thermosetting resin impregnation step serves as a preliminary action that partially saturates the decorative paper before the final second resin impregnation. This preliminary treatment ensures that paper fibers are already bonded and stabilized, preventing splitting during the subsequent lamination process while allowing the final resin step to complete the saturation for optimal bonding
2Ease of manufacture
If traditional analog printing methods are used, then manufacturing cost is reduced, but minimal order quantities increase and flexibility decreases
Solution Approach 1:
The patent changes the parameter of printing technology from traditional analog methods to digital printing, which fundamentally alters the production capabilities. This parameter change enables flexible, low-cost production of customized decorative patterns without the high minimal order quantities associated with analog printing, while the multi-resin impregnation process ensures the bonding quality required for reliable manufacturing
3Device complexity
If single resin impregnation is used, then process simplicity is maintained, but paper splitting risk increases due to insufficient resin saturation
Solution Approach 1:
The patent segments the resin impregnation process into two distinct steps with different resins. The first thermosetting resin provides initial saturation and bonding, while the second thermosetting resin completes the saturation process. This segmentation ensures comprehensive resin penetration and bonding of paper fibers, eliminating paper splitting risk while maintaining reasonable process complexity through standardized impregnation and drying operations
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
Enhances resin absorption and lamination quality, reducing paper splitting and enabling greater flexibility in decorative panel manufacturing processes.
Implementation Method 1
impregnating said decorative paper with a first thermosetting resin... impregnating said decorative paper with a second thermosetting resin
Data Source
AI summary
A method for manufacturing a laminate assembly may involve providing a decorative paper, impregnating the decorative paper with a first thermosetting resin, and laminating the resin provided decorative paper on a substrate. The decorative paper may be impregnated with a second thermosetting resin before being laminated.