Digital Inkjet Printing on Paper Layers for Decorative Panels
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Solution Overview
Problem
Existing methods for manufacturing decorative panels with printed patterns face challenges such as inflexibility in design changes, issues with resin expansion, and poor printing quality due to analog printing processes and substrate inhomogeneities.
Innovation Solution
A method involving digital inkjet printing of a wood motif pattern on a paper layer, which is then treated with thermosetting resin and optionally an inkjet receiver coating, where the resin application, printing, and coating directions are aligned to minimize defects and enhance printing quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If analog printing processes (offset or rotogravure) are used to print decorative patterns on paper, then printing quality and cost-effectiveness are improved, but flexibility in design changes deteriorates due to large minimal order quantities and long setup times (about 24 hours) for equipment exchange and cleaning
Solution Approach 1:
The patent replaces the mechanical analog printing systems (offset or rotogravure) with a digital printing system. This substitution eliminates the need for physical roller exchanges and complex equipment setup, enabling rapid design changes while maintaining printing quality through digital pattern transfer to the paper layer before resin application
Solution Approach 2:
The patent changes the fundamental parameter of the printing process from analog mechanical reproduction to digital data-based printing. This allows instantaneous design modifications without physical reconfiguration of printing equipment, solving the contradiction between maintaining printing quality and achieving design flexibility
2Strength
If resin is applied to the printed paper layer, then the decorative panel achieves structural integrity and wear resistance, but paper expansion occurs which is difficult to control and can cause defects
Solution Approach 1:
The patent applies the printing operation before resin application, allowing the paper layer to be fully printed and stabilized before the resin is applied. This preliminary action sequence enables better control of paper expansion since the printing is completed before the resin-induced expansion occurs, and the printed pattern is locked in place
Solution Approach 2:
The patent introduces an intermediary approach by printing the pattern on the paper layer first, then applying resin as a separate subsequent step. This intermediary sequencing allows the paper to be prepared with its decorative layer before the resin binding process, enabling better control over expansion and preventing resin-related defects from affecting the printed pattern
3Stability of the object's composition
If direct printing on the plate substrate is performed to avoid paper expansion, then paper expansion issues are eliminated, but printing quality deteriorates due to telegraphing of internal inhomogeneities and inferior print quality
Solution Approach 1:
The patent uses the paper layer as an intermediary medium between the printing process and the final decorative panel. By printing on the paper layer first (which provides a stable, uniform surface) and then applying resin, the system avoids direct printing on the substrate while maintaining printing quality. The paper layer acts as a buffer that prevents telegraphing of substrate inhomogeneities
4Adaptability or versatility
If digital inkjet printing is used to improve flexibility in design changes, then adaptability is improved, but printing quality and reliability deteriorate due to nozzle clogging from dust and evaporation of ink vehicle
Solution Approach 1:
The patent applies a primer or preparatory coating to the paper layer before digital printing. This preliminary action creates a protective, dust-resistant surface that prevents nozzle clogging during the printing process, thereby improving printing reliability while maintaining the flexibility benefits of digital printing
Solution Approach 2:
The patent introduces a primer layer as an intermediary between the digital printing system and the paper layer. This primer acts as a protective barrier that prevents dust from reaching the print head nozzles and prevents evaporation issues, thereby improving the reliability of digital printing while preserving design flexibility
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 method improves flexibility in design changes, reduces the impact of resin expansion and printing defects, and achieves high-quality decorative panels with enhanced wear resistance and natural wood-like appearance.
Implementation Method 1
providing said paper layer with at least a portion of said printed pattern by means of a digital inkjet printer
Implementation Method 2
providing said paper layer with thermosetting resin
Data Source
AI summary
A method is provided for manufacturing a paper layer having a printed pattern for use in panels that at least include a substrate and a top layer. The top layer includes the paper layer. The method may involve providing the paper layer with an inkjet receiver coating by transporting the paper layer relative to a coater in a coating direction. The coated paper layer may be provided with at least a portion of the printed pattern using a digital inkjet printer that includes a housing containing print heads. Providing the printed pattern may involve using water based pigment containing inks. The printed pattern may include a wood motif having wood nerves extending generally in a nerve direction substantially corresponding to the coating direction. Providing the printed pattern may involve a relative motion between the digital inkjet printer and the paper layer during a printing operation in a printing direction substantially corresponding or substantially opposite to the coating direction. The paper layer may be maintained flat inside the housing, or the minimum radius over which the paper layer is bent inside the housing may be larger than 25 centimeters. The paper layer may be fed from a roll, printed upon, and rolled back up again. The inkjet receiver coating may be obtained from a liquid substance that is deposited on the paper layer. The liquid substance may have a viscosity of 10 to 75 seconds Din cup 4 at 20° C.