Digital Printing Laminate Production Line with Real-Time Deformation Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing laminate products face challenges such as limited interaction between the decor application and resin application processes, leading to deformation issues and the need for large stockpiles of printed decor sheets, which result in inefficiencies and inconsistencies in the final product.
Innovation Solution
Performing the decor application and resin application processes in-line, allowing for simultaneous processing of the decor sheet on a continuous production line, with real-time feedback and control to adjust for deformation, ensuring precise alignment and dimensions of the motif post-resin application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If decor sheets are printed in advance and stored in large stockpiles, then production continuity is maintained, but storage space requirements and inventory costs increase
Solution Approach 1:
The patent implements a continuous production line where digital printing and resin application occur sequentially without interruption. The decor carrier moves continuously through the printing zone and immediately into the resin application zone, eliminating the need for intermediate storage of printed decor sheets. This continuous flow maintains production continuity while minimizing inventory requirements.
Solution Approach 2:
The patent merges the decor printing process and resin application process into a single integrated production line. The digital printer and resin applicator are positioned adjacent to each other, allowing the decor carrier to be printed and resin-coated in one continuous operation. This combination eliminates the separate storage step that would otherwise be required between printing and resin application.
2Measurement precision
If decor is printed before resin application, then printing quality is maintained, but deformation occurs during resin application affecting motif alignment
Solution Approach 1:
The patent applies preliminary action by having the digital printer mark reference positions and print the decor on the decor carrier before resin application. The printing process includes placing registration marks that account for expected deformation. By preparing the decor with awareness of future deformation, the system can compensate for shape changes and maintain alignment precision.
Solution Approach 2:
The system uses feedback by detecting the actual position of the decor motif after resin application and using this information to adjust subsequent printing operations. Sensors monitor the decor carrier position and deformation, and this data is fed back to the digital printer to correct alignment in real-time, ensuring precise motif alignment despite deformation during resin application.
3Productivity
If traditional rotary printing is used, then production speed is maintained, but flexibility to switch between motifs is limited
Solution Approach 1:
The patent replaces the mechanical rotary printing system with a digital printing system. Instead of using physical printing cylinders that must be physically changed to switch motifs, the invention uses digital printers that can change motifs by loading different digital files. This substitution maintains production speed while dramatically increasing flexibility to switch between different decor motifs without mechanical reconfiguration.
Solution Approach 2:
The digital printing system provides dynamic adaptability, allowing the production line to respond to changing requirements in real-time. The system can dynamically switch between different motif designs, patterns, and configurations by simply changing the digital print data, enabling rapid adaptation to different product specifications while maintaining continuous production flow.
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 enables smoother production, reduces the need for large stockpiles, allows for seamless switching between motifs, and ensures accurate alignment and dimensions of the final laminate product, particularly important for products with registered embossed surfaces.
Implementation Method 1
The decor is applied by means of one or more inkjet printers
Implementation Method 2
The decor sheet is provided with an amount of resin by impregnating it with resin, either by immersing it in liquid resin, or by depositing resin thereon
Implementation Method 3
after which the resin is dried
Data Source
Figure 1~3
Figure 4
Figure 5
AI summary
Method for manufacturing a laminate product comprising at least a laminate layer (1) with a decor sheet (2), wherein, for forming the laminate layer (1), at least a decor sheet (2) is formed by providing in a decor application process (6) a decor (5) in the form of a motif on a decor carrier (4), wherein this decor carrier (4) consists of a continuous material web, characterized in that the decor (5) is applied by means of one or more digital printers and that the global decor (5) during the processing of the material web is controlled in a varying manner, by means of controlling the one or more printers, such in function of varying external data.