Digital Printing Panel Decor Layer Adhesion via Cross-Linking
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Solution Overview
Problem
Existing methods for creating imprinted panels, particularly those mimicking real wood surfaces, face challenges in achieving high-quality print images and adequate mechanical resistance due to issues with layer adhesion and resolution, especially when using digital printing techniques.
Innovation Solution
The use of digital four-color printing with specific color point sizes and a curtain coating method for applying a primer, followed by surface treatments like corona or plasma treatment, and the application of an oil with a high unsaturated fatty acid content, enhances the quality of the print image and improves layer adhesion through chemical cross-linking during polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If digital printing is used to create decor layers on panels, then manufacturing complexity and cost are reduced, but print image quality and resolution are insufficient to effectively mimic real wood surfaces
Solution Approach 1:
The patent optimizes digital printing parameters including color point size (1000-15000 μm²), dpi value (200-1200), and ink composition to achieve high-quality wood surface imitation while maintaining digital printing's manufacturing advantages
Solution Approach 2:
The patent uses composite printing inks containing polymerizable compounds that cross-link during curing to form a network structure, enhancing both print image quality and mechanical resistance while maintaining ease of manufacture
2Strength
If multiple polymer layers are applied to improve abrasion resistance, then mechanical resistance is enhanced, but adhesion between layers becomes problematic
Solution Approach 1:
The patent combines multiple polymer layers with a decor layer containing polymerizable compounds into a single cross-linked network system, ensuring strong interlayer adhesion while maintaining high abrasion resistance
Solution Approach 2:
The patent creates a composite structure where the decor layer acts as both decorative element and adhesive promoter, containing polymerizable compounds that chemically bond with overlying polymer layers to ensure strong adhesion
3Reliability
If plasma or corona treatment is applied to improve surface adhesion, then layer adhesion is enhanced, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent enables the decor layer to self-promote adhesion through its own polymerizable compounds that cross-link with subsequent polymer layers, eliminating the need for external plasma or corona treatment equipment
Solution Approach 2:
The patent extracts the adhesion-promoting function from separate plasma/corona treatment processes and integrates it directly into the decor layer composition through polymerizable compounds
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 high-quality print images that effectively mimic real wood surfaces with improved mechanical resistance and adhesion, reducing the need for expensive plasma or corona treatments and enhancing the overall performance of the panel layers.
Implementation Method 1
whereby the surface of the primer is treated by means of at least one of the following measures: a corona treatment; a plasma treatment
Implementation Method 2
whereby the surface of the primer is treated by means of at least one of the following measures: a corona treatment; a plasma treatment
Implementation Method 3
improves layer adhesion through chemical cross-linking during polymerization
Implementation Method 4
The printing ink is based on a polymerizable acrylate and comprises cross-linking promoters, in particular fatty acids with a high proportion of unsaturated fatty acids
Data Source
AI summary
A printed image for the decor of a panel and a method for imprinting plates, in particular wall, ceiling or floor panels. The method includes the following steps: (i) providing a plate; (ii) applying a primer by means of a liquid curtain of coating material on/to a main surface of the plate; (iii) optionally drying and/or curing the primer; (iv) treating the surface of the primer by means of at least one of the following measures: a) corona treatment; b) plasma treatment; c) applying an oil in an aqueous dilution and (v) applying a decorative decor.