Inkjet Decorative Laminate Manufacturing with Ink Acceptance Layer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of decorative laminates using inkjet technology faces challenges with adhesion issues between the ink layer and the protective layer containing melamine, particularly at high ink coverages, and dimensional instability of decor paper, which affects the alignment of wood grain patterns during heat pressing.
Innovation Solution
A method involving the use of an aqueous or solvent-based pigmented inkjet ink on an ink acceptance layer with a specific ratio of inorganic pigment to polymeric binder, applied to a fully impregnated base paper, which enhances dimensional stability and adhesion, allowing for in-house printing and eliminating the need for intermediate processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If acrylate based inkjet inks are used for printing decorative patterns, then excellent image quality is achieved, but adhesion problems occur between the ink layer and the protective layer containing melamine resin
Solution Approach 1:
The patent introduces an intermediate layer between the acrylate inkjet ink layer and the melamine protective layer. This intermediate layer acts as a mediator that allows water vapor produced during melamine polycondensation to escape while maintaining the adhesion between the ink layer and protective layer, thus preventing delamination while preserving excellent image quality
Solution Approach 2:
The patent modifies the chemical composition and physical properties of the intermediate layer to control its permeability to water vapor. By adjusting parameters such as polymer type, crosslinking degree, and layer thickness, the intermediate layer is optimized to allow water vapor transmission during curing while maintaining mechanical adhesion
2Measurement precision
If decor paper is printed by solvent based or aqueous inkjet inks before impregnation, then good image quality is obtained, but dimensional instability occurs affecting wood grain alignment during heat pressing
Solution Approach 1:
The patent applies the inkjet printing process after the paper has been impregnated with thermosetting resin and dried, rather than before impregnation. This preliminary impregnation and drying step stabilizes the paper dimensions, preventing warping and ensuring proper alignment during subsequent heat pressing, while still allowing high-quality inkjet printing to be performed
3Reliability
If gravure printing is used for manufacturing decorative paper rolls, then consistent quality is achieved, but production flexibility and ability to make short runs is limited
Solution Approach 1:
The patent replaces the mechanical gravure printing system with a digital inkjet printing system. This substitution eliminates the need for physical printing plates and allows for direct digital printing from computer files, enabling rapid changeover between different decorative patterns and facilitating short production runs while maintaining quality consistency through digital precision
4Productivity
If a warehouse is maintained to store decor paper rolls with different patterns, then ability to meet sudden market demand is improved, but storage costs and time delays are increased
Solution Approach 1:
The patent enables the floor laminate manufacturer to produce decorative patterns in-house using digital inkjet printing, eliminating the need to store multiple pre-printed decor paper rolls in a warehouse. The manufacturer can directly print required patterns on demand, reducing storage requirements and delivery time delays while maintaining the ability to meet sudden market demands
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 results in excellent image quality and adhesion, enabling perfect alignment of wood grain patterns, simplifying the manufacturing process, reducing storage needs, and improving cost-efficiency by allowing for rapid design changes and reduced paper loss.
Implementation Method 1
The ink acceptance layer contains an inorganic pigment and a polymeric binder
Implementation Method 2
adhesion problems are observed between the ink layer and the protective layer
Implementation Method 3
the water vapour produced during the polycondensation of the melamine cannot penetrate through the polymerized acrylate ink layer
Implementation Method 4
the water vapour produced during the polycondensation of the melamine
Data Source
Figure 1~4
Figure 5
Figure 6
AI summary
A method for manufacturing decorative laminates including the steps of: a) impregnating a paper substrate with a thermosetting resin by submersion of the paper substrate in a bath of thermosetting resin; b) applying on the thermosetting resin impregnated paper substrate an ink acceptance layer containing an inorganic pigment P and a polymeric binder B having a weight ratio P/B of inorganic pigment to polymeric binder of larger than 1.5; c) jetting on the ink acceptance layer a colour pattern with one or more aqueous pigmented inkjet inks and/or organic solvent based pigmented inkjet inks containing a colour pigment C; and d) heat pressing the thermosetting paper into a decorative laminate, wherein the weight ratio P/C of the inorganic pigment of the ink acceptance layer to the jetted colour pigment in the colour pattern is larger than 4.0.