Digital Printing Compensation for Synchronous-Pore Laminates
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Solution Overview
Problem
Conventional laminate production processes fail to account for dimensional changes in substrates during various production steps, leading to quality defects and material loss due to mismatched decorative surfaces and structural elements.
Innovation Solution
A method that integrates digital printing with continuous data monitoring and adjustment, using sensors to measure and correct dimensional deviations of decorative papers throughout the production process, ensuring precise alignment with structural elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dimensional changes in substrate are not compensated during production steps, then production process is simple, but manufacturing precision deteriorates with fluctuations up to 10 mm
Solution Approach 1:
The patent applies preliminary action by determining correction factors for dimensional changes before the actual printing and production process. The system pre-calculates how the substrate will expand or contract based on humidity and temperature data, and adjusts the digital printing pattern accordingly in advance, preventing alignment errors before they occur.
Solution Approach 2:
The patent implements feedback by continuously monitoring humidity and temperature during production and using this data to dynamically adjust correction factors. Sensors provide real-time information about environmental conditions, which the system uses to modify the alignment compensation in real-time, ensuring consistent precision despite varying conditions.
2Manufacturing precision
If conventional positioning methods with cutting marks are used, then device complexity is low, but manufacturing precision deteriorates with only 5-10 mm correction capability
Solution Approach 1:
The patent replaces the mechanical positioning system (cutting marks and manual alignment) with a digital printing system that uses correction factors. Instead of physically marking and manually aligning papers, the system digitally calculates and applies precise positioning adjustments through the printing process itself, achieving sub-millimeter accuracy.
Solution Approach 2:
The patent applies parameter changes by modifying the digital printing parameters (position, scale, orientation) based on calculated correction factors. The system adjusts the printed pattern's geometric parameters to compensate for substrate dimensional changes, transforming the alignment problem from a mechanical to a digital parameter adjustment task.
3Manufacturing precision
If digital printing with correction factors is implemented, then manufacturing precision improves to achieve synchronous pores, but device complexity increases with data monitoring and adjustment systems
Solution Approach 1:
The patent applies universality by designing the control system to perform multiple functions: it monitors environmental conditions, calculates correction factors, stores historical data, and adjusts printing parameters all within a single integrated system. This multi-functional approach reduces the need for separate dedicated devices for each function.
Solution Approach 2:
The system applies self-service by automatically determining correction factors and adjusting printing parameters without requiring manual intervention. The control system autonomously processes sensor data, calculates the necessary adjustments, and implements them through the digital printing system, reducing the need for operator involvement.
4Manufacturing precision
If dimensional changes are not accounted for, then production speed is high, but manufacturing precision deteriorates causing material loss
Solution Approach 1:
The patent applies preliminary action by pre-calculating and applying correction factors before production errors occur. By determining the appropriate dimensional adjustments in advance based on environmental data and substrate characteristics, the system prevents misalignment and the need for rework, maintaining high production speed while ensuring precision.
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
Enables the production of laminates with synchronous pores, reducing waste and improving the consistency of decorative and structural alignment, thereby achieving higher quality and efficiency in laminate manufacturing.
Implementation Method 1
The aqueous inks used, in combination with the web tension in the printing machine, cause the paper to stretch both lengthwise and widthwise.
Implementation Method 2
The inks are then dried using warm air, IR radiators, etc., which may lead to the paper drying out and the associated shrinkage of the printed paper.
Implementation Method 3
In this production step, too, the printed paper initially stretches due to swelling and web tension.
Implementation Method 4
The paper is then dried in a drying tunnel to a processing moisture content of, for example, approx. 6 wt%, whereby the dimensional change in width is reduced to, for example, approx. 1.5% and in length to, for example, approx. 0.5%.
Implementation Method 5
In both processes, high pressures and high temperatures melt and crosslink the synthetic resins and thus the individual impregnated papers.
Implementation Method 6
high pressures and high temperatures melt and crosslink the synthetic resins
Data Source
AI summary
The invention relates to a method for producing laminates with synchronized pores, comprising the steps: a) producing a laminate, comprising the steps i. printing a substrate, preferably a decorative paper, by means of digital printing and storing the print and/or position data of the printed decoration; ii. drying the printed substrate; iii. applying and drying an impregnation to the printed substrate; iv. producing a laminate, comprising pressing the printed and impregnated substrate together with impregnated core layers and optionally an overlay and optionallya protective layer using a structuring element, wherein the structuring element is a paper-based structuring element or a structuring tape; b) measuring the dimensions of the structuring element; c) measuring the dimensions of the substrate material; d) determining deviations of the dimensions of the substrate material from the dimensions of the structuring element; e) calculating at least one partial correction factor, which represents the deviation in the length and/or width of the substrate material from the length and/or width of the substrate material after passing through one of the process steps a)i. to a)iv.; f) controlling one or more process parameters based on the determined partial correction factors in order to adjust the determined deviations in the dimensions of the substrate material in preceding or subsequent process steps. The invention further provides a device for carrying out this method.