Decorative Paper Layer Structure for Resin Seepage Control

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Solution Overview

Problem

Conventional decorative papers and boards face issues with reduced design quality due to seepage of liquid-repellent cured films into the base paper, leading to impaired impregnability and solvent resistance.

Innovation Solution

A decorative paper structure comprising a primary film layer, a pattern-printed layer, a high-design-quality protective layer on part of the pattern-printed layer, and a high-design-quality resin layer matching the protective layer, with the protective layer's coated area ranging between 0.5 to 1.5 times that of the resin layer, inhibiting resin seepage and ensuring sufficient impregnation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a liquid-repellent cured film is provided on the pattern layer to achieve gloss-adjusted design, then design quality is improved, but the cured film seeps into the base paper causing reduced design quality and impaired impregnability

Engineering Contradiction:

Improvedesign qualityVSAvoidimpregnability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

A release layer is introduced as an intermediary between the pattern layer and the liquid-repellent cured film. This release layer prevents the cured film from seeping into the base paper while still allowing the gloss-adjusted design to be achieved, thereby resolving the contradiction between design quality and impregnability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The structure is segmented into distinct layers: base paper, pattern layer, release layer, and liquid-repellent cured film. This segmentation isolates the cured film from direct contact with the base paper, preventing seepage while maintaining both design quality and impregnability

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If a coating layer is provided between the decorative layer and the surface layer to achieve gloss-adjusted design, then design quality is improved, but the coating layer inhibits impregnation with melamine resin reducing impregnability and solvent resistance

Engineering Contradiction:

Improvedesign qualityVSAvoidimpregnability

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The release layer serves as a mediator that allows the liquid-repellent cured film to be applied without directly contacting the base paper. This intermediary layer prevents the coating from blocking resin impregnation while still enabling the gloss-adjusted design to be achieved

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The release layer is strategically positioned only where needed to prevent seepage, allowing different regions of the decorative paper to have different properties: the pattern layer region has the release layer for design quality, while the base paper remains accessible for resin impregnation

Inventive Principle:

Principle #3Local 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 results in decorative papers and boards with improved design quality and impregnability, exhibiting enhanced solvent resistance and consistent gloss or mat appearance.

Implementation Method 1

a high-design-quality protective layer provided on part of the pattern-printed layer; and a high-design-quality resin layer provided on the high-design-quality protective layer to match the high-design-quality protective layer

Methodology Applied

Scientific EffectPhysical barrier layer:

Implementation Method 2

Methodology Applied

Scientific EffectImpregnation:

Data Source

PatentUS20260054517A1Decorative paper, decorative board, and methods for producing decorative paper and decorative board

Publication Date: 2026.02.26 TOPPAN HOLDINGS INC

AI summary

A decorative paper includes a primary film layer, a pattern-printed layer provided on the primary film layer, a high-design-quality protective layer provided on part of the pattern-printed layer, and a high-design-quality resin layer provided on the high-design-quality protective layer to match the high-design-quality protective layer. A decorative board includes the decorative paper and an impregnation resin used for impregnating the decorative paper and cured therein.