Resin-Impregnated Decorative Paper Filling Layer Barrier
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Solution Overview
Problem
The existing methods for manufacturing resin-impregnated decorative plates are costly due to the need for preparing metal plates for each uneven pattern, and they often compromise on gloss matte expression and touch feeling due to foamed resin soaking into the base paper.
Innovation Solution
A resin-impregnated decorative paper is created with a base paper, a picture pattern layer, a filling layer containing epoxy-based, acrylic-based, or urethane-based resin, and a foamed resin layer formed by a foaming agent, which is integrated with a base member using heat pressure molding to form a decorative plate without the need for individual metal plates, thereby maintaining excellent gloss matte expression and touch feeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If foamed resin layers are provided to give uneven patterns, then cost is reduced by eliminating metal plates, but foamed resin soaks into base paper causing loss of touch feeling and gloss matte expression
Solution Approach 1:
A filling layer made of thermoplastic resin is introduced as an intermediary between the base paper and the foamed resin layer. This filling layer acts as a barrier that prevents the foamed resin from soaking into the base paper during heat pressure molding, thereby maintaining the touch feeling and gloss matte expression while still using the cost-effective foamed resin method
2Ease of manufacture
If foamed resin layers are provided to give uneven patterns, then cost is reduced by eliminating metal plates, but foamed resin soaks into base paper causing loss of gloss matte expression
Solution Approach 1:
The filling layer serves as a protective intermediary that blocks the foamed resin from penetrating into the base paper. This prevents the base paper from becoming rough or damaged, thereby preserving the gloss matte expression on the surface while still utilizing the economical foamed resin approach
3Manufacturing precision
If metal plates are prepared for each uneven pattern, then touch feeling and gloss matte expression are maintained, but manufacturing cost increases
Solution Approach 1:
Instead of using expensive custom-made metal plates for each uneven pattern design, the invention uses a standardized foamed resin layer that can be easily molded into different patterns. The filling layer ensures that the visual and tactile quality matches what would be achieved with metal plates, while significantly reducing manufacturing cost through a more versatile and economical process
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 method allows for cost-effective production of resin-impregnated decorative plates with enhanced gloss matte expression and touch feeling by preventing foamed resin from soaking into the base paper, while maintaining design properties and adhesion.
Implementation Method 1
a foamed resin layer provided on a surface of the filling layer, the foamed resin layer formed by a foaming agent
Implementation Method 2
it is possible to foam a foaming agent by heat pressure molding to properly form an uneven pattern on a surface of a resin-impregnated decorative paper
Implementation Method 3
since a foamed resin having affinity with an impregnating resin such as a melamine resin easily soaks into a base paper
Data Source
AI summary
There is provided a resin-impregnated decorative paper (2) formed by impregnating a decorative paper (4) with an impregnating resin (5). The decorative paper (4) includes: a base paper (6); a picture pattern layer (7) provided on a surface (6a) side of the base paper (6); a filling layer (8) provided on a surface (7a) of the picture pattern layer (7); and a foamed resin layer (9) provided on a surface (8a) of the filling layer (8). The filling layer (8) contains at least one of an epoxy-based resin, an acrylic-based resin, a urethane-based resin, and a casein-based resin.