Resin Impregnated Decorative Paper Foamed Texture
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Solution Overview
Problem
Existing methods for producing resin impregnated decorative panels require preparing a metal plate for each uneven pattern, leading to increased costs and potential contamination and design stability issues during long-term storage.
Innovation Solution
A resin impregnated decorative paper sheet is created with a base paper sheet, a pattern layer, a foamed resin layer formed by a foaming agent, and a thermosetting resin layer containing epoxy, casein, or acrylic resin, which is integrated with a base material using heat press molding to form a panel with a gross matte expression and improved contamination resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a metal plate with embossed shape is used to impart uneven pattern, then hand touch feeling and gross matte expression are improved, but cost increases due to preparation of metal plate for each pattern
Solution Approach 1:
The invention uses a foamed resin layer as a copy or alternative to the metal plate embossed shape. Instead of requiring actual metal plates with embossed patterns for each design, the patent creates uneven patterns through foaming agents that expand during curing, replicating the desired surface texture and hand touch feeling without the need for expensive, custom-made metal plates.
2Ease of manufacture
If a foamed resin layer is used to impart uneven pattern, then cost is reduced, but contamination resistance and design stability deteriorate due to unprotected raised parts
Solution Approach 1:
The invention creates a composite structure where a thermosetting resin layer is applied over the foamed resin layer. This upper resin layer serves as a protective coating that shields the raised, unprotected parts of the foamed resin layer from contamination and damage, while still allowing the underlying uneven pattern to provide cost-effective gross matte expression and hand touch feeling.
3Ease of manufacture
If a foamed resin layer is used to impart uneven pattern, then cost is reduced, but design stability after long-term storage deteriorates due to unprotected raised parts
Solution Approach 1:
The protective thermosetting resin layer forms a durable composite structure that preserves the design stability of the uneven pattern over long-term storage. This coating prevents degradation, oxidation, and damage to the exposed surfaces of the foamed resin layer, ensuring that the gross matte expression and hand touch feeling remain intact throughout the product's service life.
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 panels with excellent hand touch feeling and design stability, as the foamed resin layer is protected by the thermosetting resin layer, maintaining performance over long-term storage.
Implementation Method 1
a foamed resin layer formed by a foaming agent arranged on the surface of the pattern layer or in the pattern layer
Implementation Method 2
a thermosetting resin layer provided on the surface of the foamed resin layer, in which the thermosetting resin layer contains at least one of an epoxy resin, a casein resin, an acrylic resin, and a urethane resin
Data Source
AI summary
There is provided a resin impregnated decorative paper sheet (2) in which a decorative paper sheet (4) is impregnated with an impregnation resin (5). The decorative paper sheet (4) includes: a base paper sheet (6); a pattern layer (7) provided on a surface (6a) side of the base paper sheet (6); a foamed resin layer (8) formed by a foaming agent arranged on a surface (7a) of the pattern layer (7) or in the pattern layer (7); and a thermosetting resin layer (9) provided on a surface (8a) of the foamed resin layer (8). The thermosetting resin layer (9) contains at least one of an epoxy resin, a casein resin, an acrylic resin, and a urethane resin.