Digital Inkjet Printing for Decorative Panel Coating
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Solution Overview
Problem
Existing methods for decorative coating of panel-shaped materials face limitations in flexibility and cost due to long set-up times and large batch size constraints, as well as inefficiencies in the multi-step process of printing, impregnating, and pressing decorative paper.
Innovation Solution
A method utilizing a digital printing machine with inkjet technology to print decorative paper in real-time during the continuous coating process, allowing for immediate application and processing of the exact amount needed, enabling production of small batch sizes without interrupting production and reducing the number of process steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional printing methods are used to produce decorative paper in large batches, then production speed and manufacturing efficiency are improved, but flexibility to produce small batch sizes and customization is reduced
Solution Approach 1:
The patent applies digital printing technology that creates decorative patterns by depositing pigment onto decorative paper in a digital format. This allows for on-demand production of exact reproductions of design patterns without requiring physical molds or plates, enabling small batch sizes and customizations while maintaining high production speeds through digital file-based reproduction
Solution Approach 2:
The patent changes the printing method from traditional analog printing to digital printing, allowing continuous adjustment of design parameters, colors, and patterns without physical retooling. This enables flexible production of small batches with unique designs while maintaining the efficiency of continuous production processes
2Manufacturing precision
If multiple separate process steps (printing, impregnating, pressing) are used, then manufacturing precision and quality control are improved, but process complexity and production time are increased
Solution Approach 1:
The patent combines the printing process with the impregnation and pressing operations into an integrated system. The digital printing machine deposits pigment onto decorative paper that is simultaneously being impregnated with resin and prepared for pressing, reducing the number of separate equipment and process steps while maintaining quality control through coordinated operation of all functions
Solution Approach 2:
The patent creates a multi-functional production line where a single integrated system performs printing, impregnation, and pressing operations. This universal approach allows one equipment to handle multiple process steps that were previously requiring separate machines, reducing overall process complexity while maintaining manufacturing precision
3Productivity
If decorative paper is printed in advance and stored, then production speed is improved, but material waste and storage costs increase
Solution Approach 1:
The patent prepares decorative paper for printing with preliminary treatments and positioning systems in place, but the actual printing occurs at the point of use during the coating process. This allows the system to maintain readiness for rapid production while printing only the exact amount needed, eliminating waste from over-production and stored inventory
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 approach enhances flexibility by enabling production of small batch sizes down to batch size 1 without interruptions, reduces costs by minimizing excess material production, and streamlines the process by integrating printing directly into the coating operation.
Implementation Method 1
a digital printing machine with inkjet technology to print decorative paper in real-time
Implementation Method 2
The decorative paper printed in this way is then impregnated with a resin, preferably a melamine resin, and dried
Implementation Method 3
the printed and impregnated paper is pressed onto a wood-based panel
Implementation Method 4
the corresponding resin, preferably melamine resin, reacts. It is also said that it condenses, so that a very resistant surface is created
Data Source
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AI summary
The invention relates to a method for decoratively coating a board, particularly a wood material board, comprising the steps of: - transporting a board (1) to a coating station; - feeding a decorative paper into a printing machine (5) and imprinting the decorative paper (7); - placing the imprinted decorative paper (7) on the board (1); - coating the decorative paper with a resinous coating, and - pressing the unit made of the board, decorative paper, and resinous coating. The decorative paper can thus be matched to the respective coating as part of the coating process, so that even small batches can be manufactured effectively.