Building Panel Sub-Layer Impregnation for Reduced Ink Bleeding
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Solution Overview
Problem
Digital printing on resin-impregnated paper sheets for laminate flooring results in poor printing quality due to bleeding and uneven ink distribution, and existing methods struggle to achieve uniform impregnation without compromising the integrity of the paper.
Innovation Solution
A method involving a thermosetting binder applied in dry form as a sub-layer beneath the sheet, which impregnates the sheet from below during pressing, allowing for improved adherence and reduced ink bleeding by maintaining the sheet unimpregnated and permeable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the paper sheet is impregnated with liquid resin before printing, then the paper sheet gains adhesion strength, but the printing quality deteriorates due to ink bleeding and uneven ink distribution
Solution Approach 1:
The patent divides the impregnation process into two separate stages: first, the paper sheet is impregnated with thermosetting resin and cured to form a stable base layer; second, a separate decorative layer is applied and cured. This segmentation prevents ink bleeding during printing while maintaining adhesion strength, as the first impregnated layer provides structural support without interfering with the printing of the decorative layer.
Solution Approach 2:
The patent applies preliminary impregnation with thermosetting resin and curing before the printing step. By pre-curing the resin in the paper sheet, the material becomes stable and less prone to ink bleeding during subsequent printing operations, thereby improving printing quality while maintaining adhesion.
2Manufacturing precision
If a uniform unimpregnated layer is created for receiving the print, then printing quality improves, but it becomes difficult to secure uniform impregnation
Solution Approach 1:
The patent separates the impregnation function from the printing function by using two distinct layers: the first layer is uniformly impregnated with thermosetting resin for structural stability, while the second decorative layer remains unimpregnated or lightly impregnated to receive the print. This segmentation allows each layer to be optimized for its specific function without compromising the other.
Solution Approach 2:
The patent introduces a separate decorative layer as an intermediary between the impregnated base layer and the print. This decorative layer serves as the printing surface, allowing the print to be applied uniformly without requiring the base layer to be unimpregnated, thus resolving the conflict between uniform impregnation and printing quality.
3Adaptability or versatility
If digital printing is applied directly on resin impregnated paper sheets, then the flooring industry can customize decorative patterns, but ink bleeding occurs during printing and pressing
Solution Approach 1:
The patent applies preliminary impregnation with thermosetting resin and curing before the digital printing step. By pre-curing the resin, the paper sheet becomes stable and resistant to ink bleeding during printing and pressing, enabling customization while maintaining printing quality.
Solution Approach 2:
The patent separates the structural function (provided by the impregnated paper sheet) from the decorative function (provided by the digital print on the decorative layer). This segmentation allows the paper sheet to be impregnated for strength while the decorative layer provides the printing surface, enabling customization without ink bleeding.
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
Enhances printing quality by reducing ink bleeding and achieving uniform impregnation, facilitating coordination with embossed structures, and reducing the need for specialized print papers, thereby lowering costs.
Implementation Method 1
pressing the substrate, the sub-layer and the sheet together to form a building panel, thereby the thermosetting binder of the sub-layer impregnates the sheet from below
Implementation Method 2
In a piezoelectric DOD inkjet printer, the piezoelectric material changes shape when a voltage is applied. The change of shape of the piezoelectric material generates a pressure pulse in the fluid, thereby ejecting a droplet of ink from the nozzle
Implementation Method 3
In a thermal DOD inkjet printer, ink drops are ejected by forming an ink vapour bubble by heating the ink
Implementation Method 4
Different kind of inks may be used for digital printing, such as UV curable inks
Data Source
AI summary
A method to produce a building panel, including: providing a substrate, applying a thermosetting binder in dry form on the substrate for forming a sub-layer, applying a sheet on the sub-layer, and pressing the substrate, the sub-layer and the sheet together to form a building panel, thereby the thermosetting binder of the sub-layer impregnates the sheet from below. Also, a semi-finished product.