Multi-ply Web Decor-Synchronous Structuring via Pre-cured Film
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Solution Overview
Problem
Existing methods for producing composite materials with decor-synchronously structured surfaces face challenges in continuous processes due to the impossibility of matching printed decorative structures with embossing, and in discontinuous processes due to high complexity and cost-intensive investments, particularly with cellulose-containing carrier materials that exhibit hygroscopic properties and dimensional instability.
Innovation Solution
A method involving a multi-layer material web made of a curable polymeric material with a printed decorative pattern, where a plastic film is applied and a pre-curved pattern is printed on it, allowing the protrusions to penetrate and form congruent embossing during pressing, followed by curing and detachment to achieve a decor-synchronously structured surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous process with steel strips or release papers is used for surface structuring, then production efficiency is improved, but decor-synchronous matching of printed patterns with embossing becomes difficult or impossible
Solution Approach 1:
The patent applies preliminary action by pre-structuring the plastic film with relief patterns before bonding it to the printed decorative layer. This pre-structuring ensures that the embossing pattern is already prepared and will automatically align with the printed decor during the pressing process, eliminating the matching problems encountered in continuous processes with steel strips or release papers.
Solution Approach 2:
The patent uses a composite structure consisting of a printed decorative layer bonded to a plastic film with pre-formed relief patterns. This composite material approach allows the decorative print and the structural embossing to be integrated into a single unit that maintains decor-synchronous matching while enabling continuous production through efficient pressing processes.
2Manufacturing precision
If discontinuous process with structured press plates is used for surface structuring, then decor-synchronous matching is achieved, but process complexity and investment costs increase significantly
Solution Approach 1:
The patent eliminates the need for complex, custom-made structured press plates by pre-structuring simple plastic films with relief patterns. This preliminary structuring of the film itself allows the use of simple, flat pressing surfaces, dramatically reducing device complexity and investment costs while maintaining decor-synchronous matching precision.
Solution Approach 2:
The patent replaces expensive, durable structured press plates with inexpensive, disposable plastic films that have pre-formed relief patterns. These films are consumed in the pressing process, eliminating the need for costly press plate manufacturing and maintenance, thereby reducing both device complexity and investment costs.
3Ease of manufacture
If cellulose-based carrier materials are used for printed decorative structures, then decorative properties are achieved, but dimensional stability deteriorates due to hygroscopic properties
Solution Approach 1:
The patent changes the material parameter from hygroscopic cellulose-based carrier materials to dimensionally stable plastic films. This material substitution eliminates the dimensional instability caused by moisture absorption while maintaining the ability to support printed decorative structures and undergo the necessary pressing and curing processes.
Solution Approach 2:
The patent creates a composite structure where the printed decorative layer is bonded to a dimensionally stable plastic film substrate. This composite approach combines the decorative capabilities of printed materials with the dimensional stability of plastics, eliminating the hygroscopic problems of cellulose-based carriers.
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 simplifies the production of composite materials with synchronized decorative and haptic properties, enabling continuous and discontinuous production of materials with consistent and visually appealing surfaces, such as wood or stone imitations, while reducing complexity and costs.
Implementation Method 1
Applying a plastic film to the printed side of the printed material web by means of an adhesive layer
Implementation Method 2
Printing a pre-cured pattern onto the surface of the plastic film with a curable compound such that the pre-cured pattern is congruent with the printed decorative pattern
Implementation Method 3
Pressing the multilayer material web obtained in step (d) such that the surface-printed protrusion, together with the supporting plastic film, penetrates the underlying material of the multilayer web
Implementation Method 4
Applying a plastic film to the printed side of the printed material web by means of an adhesive layer or electrostatic fixation
Data Source
Figure 1(a)~1(d)
AI summary
The present invention describes a method for producing a multilayer material web with a decor-synchronously structured surface and its use in continuous or discontinuous coating systems for the production of composite materials with a decor-synchronously structured surface. According to the invention, the method leads, after appropriate application, to composite materials (laminates and/or coated wood fiber materials) that are provided with a structured decorative surface and are used as surface materials for flooring, furniture, and interior design (ceiling and wall coverings).