Resin-Impregnated Decorative Paper Curing Method
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Solution Overview
Problem
Existing methods for manufacturing resin-impregnated decorative paper face challenges such as delamination and curling issues during the production of decorative panels, which affect the adhesion and weather resistance of the final product.
Innovation Solution
A method involving the impregnation of paper with a first actinic radiation-curable resin, followed by drying to a residual moisture content of less than 5%, and then applying a second actinic radiation-curable resin, with a two-step radiation curing process using varying doses to achieve complete curing, ensuring minimal delamination and curling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the decorative paper is impregnated with resin and placed in a press under high pressure and temperature, then the decorative panel forms, but delamination occurs between the decorative paper and substrate
Solution Approach 1:
The patent applies actinic radiation-curable resins that undergo chemical transformation when exposed to actinic radiation, changing the physical and chemical parameters of the resin to achieve complete curing. This ensures optimal adhesion strength and eliminates delamination by transforming the resin from a liquid state through polymerization to a cross-linked gel state, creating a durable bond between decorative paper and substrate
Solution Approach 2:
The patent replaces traditional thermal curing mechanisms with actinic radiation curing. Instead of relying on heat and pressure to cure the resin, actinic radiation (UV or other wavelengths) directly initiates polymerization of the photopolymerizable resin, achieving complete curing without the need for high temperature and pressure conditions that cause delamination
2Shape
If the decorative paper is placed in a press, then the decorative panel is formed, but the decorative paper exhibits curling at the edges
Solution Approach 1:
The patent uses resins containing photopolymerizable groups that undergo rapid polymerization upon exposure to actinic radiation, fundamentally changing the viscosity and mechanical properties of the resin system. This parameter change allows the resin to set quickly and maintain flatness, preventing edge curling during pressing operations
Solution Approach 2:
The patent applies the actinic radiation-curable resin to the decorative paper before pressing, allowing the resin to be in a workable state during application and positioning. The resin is then cured with actinic radiation before or during pressing, preventing curling from occurring during the manufacturing process
3Reliability
If a single resin system is used for impregnation, then the process is simplified, but complete curing and weather resistance are insufficient
Solution Approach 1:
The patent employs a composite resin system where photopolymerizable resin components are combined with specific additives and modifiers to create a multi-functional material. This composite resin provides complete curing through photopolymerization while simultaneously delivering enhanced weather resistance, adhesion, and processing properties that a single-component resin could not achieve
Solution Approach 2:
The actinic radiation-curable resin system is designed to perform multiple functions simultaneously: it provides adhesion between layers, enables complete curing through photopolymerization, delivers weather resistance, and allows for precise control of the curing process. This multi-functional resin eliminates the need for separate coating and curing steps, simplifying the overall process while achieving superior performance
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 results in a resin-impregnated decorative paper with improved adhesion to the substrate, reduced curling, and enhanced resistance to weather influences, allowing for the production of decorative panels with excellent durability and color stability under severe conditions.
Implementation Method 1
impregnating the paper with a first, actinic radiation-curable resin... applying a second, actinic radiation-curable resin... curing the paper to obtain the resin-impregnated decorative paper
Data Source
AI summary
The present invention relates to a method for manufacturing a resin-impregnated decorative paper, which method comprises the following steps: i) providing a paper, ii) impregnating the paper obtained in step i) with a first, actinic radiation-curable resin, iii) subjecting the paper obtained after step ii) to a drying step, iv) applying a second, actinic radiation-curable resin to the dried paper obtained after step iii), and v) curing the paper obtained after step iv) to obtain the resin-impregnated decorative paper.