Printing Substrate for Decorative Panels
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Solution Overview
Problem
The surface of decorative panels used for direct printing is not an optimal printing substrate, as the resin used for attachment penetrates through the paper or non-woven fabric, causing adhesion issues with printing ink and subsequent stability problems in the laminate composite.
Innovation Solution
A method involving a plate-shaped carrier with a resin layer, an unprinted paper or fleece layer, and calendering at specific temperatures, followed by application of a resin composition with controlled solids content and pigments, which penetrates partially to enhance adhesion and stability, suitable for various printing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If resin layer is applied to carrier and paper/fleece layer is attached directly for printing, then production process is simple, but resin penetrates through paper causing poor ink adhesion and laminate instability
Solution Approach 1:
A printing substrate is applied to the paper or fleece layer before printing takes place. This printing substrate serves as an intermediate layer that prevents resin penetration while providing optimal ink reception properties, thereby ensuring both good ink adhesion and laminate stability without complicating the overall production process
2Reliability
If printing substrate with solids content between 5-85% is applied after calendering, then ink adhesion and laminate stability are improved, but process complexity increases
Solution Approach 1:
The printing substrate is characterized by a specific solids content range (5-85%) and particle size distribution (d50 between 0.1-120 μm). By controlling these parameters, the substrate achieves optimal ink adhesion and laminate stability while integrating smoothly into the existing production process
3Strength
If conventional decorative paper with overlay is used, then adhesion is maintained, but direct printing capability is lost and production time increases
Solution Approach 1:
The printing substrate is applied directly to the paper or fleece layer without requiring a separate decorative paper pre-printed with decoration and without requiring an overlay layer. The decoration is printed directly onto the printing substrate, eliminating unnecessary layers and steps while maintaining adhesion through the substrate's resin composition and particle structure
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
The method provides a surface suitable for direct printing with excellent ink adhesion and stability, ensuring a high-stability laminate with improved adhesion of subsequent cover layers, suitable for flexographic, offset, screen, and digital printing.
Implementation Method 1
calendering at specific temperatures
Implementation Method 2
calendering at specific temperatures
Implementation Method 3
resin composition which penetrates partially to enhance adhesion
Implementation Method 4
resin used for attachment penetrates through the paper or non-woven fabric, causing adhesion issues
Data Source
Figure 1
AI summary
Producing a printing material (140) for directly printing on a decorative panel (100), comprises (a) providing a plate-shaped carrier (110), (b) applying a resin layer (120) to the plate-shaped carrier, (c) applying a paper or fleece layer (130) of the plate-shaped carrier, and (d) calendering the resulting layered structure at a temperature of 40-250[deg] C. A resin composition comprising 0.5-85 wt.%, preferably 1-80 wt.% solid having an average particle diameter of 0.1-120 mu m is applied after calendering. An independent claim is also included for the direct printed decorative panel comprising the plate-shaped carrier, the resin layer applied on the plate-shaped carrier, the layer of a non-impregnated and unprinted paper or fleece, the printing material applied to the paper or fleece layer, a color layer applied to the printing material, and a top- and/or wear-resistant layer applied on at least the color layer, where the resin composition comprises melamine resin, formaldehyde resin, urea resin, phenol resin, epoxide resin, unsaturated polyester resin and/or diallyl phthalate as a resin component in a concentration of 15-95 wt.%, preferably 20-90 wt.% and hardener in a concentration of 0.05-2 wt.%, preferably 0.15-1 wt.%.