Multilayered Board Resin Layer Thickness for High-Gloss Surfaces
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Solution Overview
Problem
The production of multilayered boards with high-gloss surfaces is limited by the need for multi-stage presses, which result in high energy consumption and long production periods, whereas short-cycle and continuous pressing methods are inefficient for achieving high-gloss surfaces due to the protrusion of paper fibers impairing reflection features.
Innovation Solution
A multilayered board design featuring a resin layer with an average thickness of at least 5 μm on the visible paper layer, ensuring that paper fibers do not project to the surface, allowing for high-gloss surface production in short-cycle and continuous presses, with optional backing and overlay paper layers to enhance smoothness and wear-resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multi-stage presses with re-cooling are used to produce high-gloss surfaces, then surface gloss quality is improved, but energy consumption increases and production time extends to 15-25 minutes
Solution Approach 1:
The invention changes the physical-chemical parameters of the resin layer by controlling its thickness (at least 5 μm) and composition, enabling the resin to form a sufficient continuous layer that fills paper fiber irregularities. This parameter optimization allows high-gloss surfaces to be achieved in short-cycle presses without requiring multi-stage processing and re-cooling, thus reducing production time while maintaining surface quality
Solution Approach 2:
The resin layer is applied in advance with sufficient thickness before the pressing process. This preliminary action ensures that when the paper is pressed in a short-cycle or continuous press, the resin is already positioned to fill the paper fiber valleys and create a smooth reflective surface, eliminating the need for subsequent re-cooling stages required in conventional multi-stage presses
2Productivity
If short-cycle or continuous pressing methods are used, then production time is reduced to 10-30 seconds or 5-10 seconds, but paper fibers protrude to the surface impairing reflection features and gloss quality
Solution Approach 1:
The critical parameter changed is the resin layer thickness, set to at least 5 μm. This thickness is sufficient to bridge and fill the valleys between protruding paper fibers during short-cycle pressing, creating a continuous smooth surface that enables high-gloss reflection. The resin composition and application parameters are optimized to ensure adequate layer formation under rapid pressing conditions
Solution Approach 2:
The resin layer acts as an intermediary substance between the paper substrate and the external environment. It fills the irregularities caused by protruding paper fibers, creating a smooth intermediate surface that enables high-gloss reflection even when the underlying paper structure remains rough. This intermediary layer decouples the surface gloss quality from the paper fiber structure
3Manufacturing precision
If resin layer thickness is increased to prevent fiber protrusion, then surface gloss is improved, but resin consumption increases
Solution Approach 1:
The invention optimizes the resin layer thickness parameter to a specific range (at least 5 μm but controlled to avoid excessive application). This optimized parameter provides the minimum necessary thickness to fill paper fiber irregularities and create a continuous reflective surface, achieving high-gloss quality while minimizing resin consumption. Further thickness increases beyond this optimized point provide diminishing returns for gloss improvement
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 high-gloss surfaces in short-cycle and continuous pressing methods, reducing energy consumption and production time while maintaining surface quality, with improved resin distribution and reduced resin usage.
Implementation Method 1
a resin layer is present on the side of the at least one paper layer or the topmost paper layer facing away from the material board, the average layer thickness of the resin layer is at least 5 μm. The resin layer according to the claims makes it possible to produce high-gloss surfaces... since an average layer thickness of at least 5 μm prevents paper fibers from projecting up to the surface of the decorative paper, thus impairing the reflection features of the surface.
Implementation Method 2
An optically high-gloss surface is thereby defined according to the standards DIN 67530, ISO 2813, ASTM D 523 and BS 3900 Part D5 such that the surface has a value of more than 60 gloss units at an angle of incidence of 20° with respect to the surface plane.
Data Source
AI summary
A multilayered board including a material board having a visible surface coated with at least one paper layer impregnated with resin. The multilayered board includes a material board, at least one paper layer structured to coat the material board, and a resin layer structured to impregnate the at least one paper layer, wherein the resin layer is arranged to face away from the material board and have an average layer thickness of at least 5 μm.