Decorative Paper Micropore Coating for Faster Resin Impregnation
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Solution Overview
Problem
Existing decorative papers and boards face issues with poor processing suitability during resin impregnation due to liquid-repellent cured films soaking into the base paper, leading to increased impregnation time and reduced design freedom.
Innovation Solution
A decorative paper design with a base layer, a design print layer, and an aesthetic resinous layer having a controlled coating area ratio of 5% to 60% and micropores, allowing efficient resin impregnation while maintaining design properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a liquid-repellent cured film is provided on the design pattern layer to achieve gloss adjustment and design properties, then the aesthetic appearance is improved, but the film soaks into the base paper causing poor resin impregnation and increased processing time
Solution Approach 1:
The aesthetic resinous layer is segmented into a coating portion that covers only part of the design pattern layer and micropores that are not coated. This segmentation allows the coating portion to provide gloss adjustment and design properties while the micropores maintain resin impregnation capability, resolving the contradiction between aesthetic appearance and manufacturing suitability.
Solution Approach 2:
Different regions of the aesthetic resinous layer have different properties: the coating portion provides gloss adjustment and design properties, while the micropores provide resin impregnation capability. This local differentiation allows each region to fulfill its specific function without compromising the other, resolving the technical contradiction.
2Ease of manufacture
If the coating amount of the liquid-repellent cured film is reduced to improve resin impregnation, then processing suitability is improved, but the degree of freedom in disposing the liquid-repellent cured film is reduced resulting in inferior design
Solution Approach 1:
The aesthetic resinous layer is segmented into a coating portion and micropores. The coating portion can be disposed with high coating amount to maintain design freedom and aesthetic properties, while the micropores ensure adequate resin impregnation. This segmentation allows both high coating amount and good impregnation to coexist, resolving the contradiction between processing suitability and design freedom.
3Manufacturing precision
If a coating layer is provided to suppress the permeation of the release layer into the paper substrate, then design properties are maintained, but the impregnation of the impregnating resin is inhibited and processing time increases
Solution Approach 1:
The aesthetic resinous layer is segmented into a coating portion that maintains design properties and micropores that allow resin impregnation. This segmentation eliminates the need for a separate coating layer that would inhibit impregnation, as the micropores naturally permit resin penetration while the coating portion maintains aesthetic properties, thus reducing processing time while maintaining design quality.
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 solution enables decorative papers and boards with excellent design properties and processing suitability by minimizing resin soakage into the base layer, ensuring rapid and uniform resin impregnation.
Implementation Method 1
an aesthetic resinous layer with excellent design properties disposed on an upper side of the design print layer, the aesthetic resinous layer having a coating portion that is coated in a coating area, and micropores that are not coated
Data Source
AI summary
Decorative paper includes: a base layer; a design print layer provided on the upper side of the base layer, and an aesthetic resinous layer with excellent design properties disposed on the upper side of the design print layer, and includes a coating portion that is coated, and micropores that are not coated and which are disposed surrounded by the coating portion.