Digital Printing Reactive Basic Layer for Fiberboard Substrates
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for digital printing on high density fiberboard substrates require separate supports, leading to costly and complex processes, and result in insufficient cohesion between layers, causing delamination under stress.
Innovation Solution
A method involving a liquid reactive composition as a basic layer that forms after evaporation of volatile components, allowing for direct digital printing and subsequent curing, which enhances cohesion and prevents delamination by acting as an adhesive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate support (paper or fleece) is used for digital printing, then the printing process can be performed, but the process becomes more costly and complex
Solution Approach 1:
The patent merges the support function and the print carrier into a single integrated layer. The print carrier layer serves both as the substrate for digital printing and as part of the final multi-layer structure, eliminating the need for separate support materials that would require additional removal or integration steps.
Solution Approach 2:
The print carrier layer is designed to perform multiple functions: it serves as the printing substrate, provides structural support during processing, and becomes an integral part of the final product's multi-layer construction. This multi-functionality eliminates the need for dedicated separate supports.
2Ease of manufacture
If a porous basic layer is used for printing, then the substrate can be prepared, but the ink is absorbed leading to insufficient covering
Solution Approach 1:
The patent applies a non-porous barrier layer specifically at the printing interface to prevent ink absorption, while other layers in the structure may have different porosity characteristics. This localized control of porosity ensures printing quality without compromising the overall substrate structure.
Solution Approach 2:
The non-porous barrier layer acts as an intermediary between the porous substrate and the ink. It prevents direct contact between the ink and porous materials that would cause absorption, while still allowing the printing process to proceed normally on its surface.
3Ease of manufacture
If a non-porous basic layer is used for printing, then the substrate can be prepared, but the ink droplets coalesce and color quality is affected
Solution Approach 1:
The patent creates a multi-layer structure where the printing surface has specific non-porous properties to prevent coalescence, while underlying layers have different characteristics. This localized differentiation allows each layer to perform its specific function optimally.
4Manufacturing precision
If multiple printing devices are used with forced drying, then the decor can be printed, but special equipment is required making the process expensive
Solution Approach 1:
The patent combines the printing and drying functions into a single integrated process step. The multi-layer structure is designed to allow ink drying within the layer stack itself, eliminating the need for separate forced drying equipment between printing passes.
5Manufacturing precision
If multiple printing devices are used, then the decor can be printed, but alignment precision is critical for quality
Solution Approach 1:
The patent consolidates multiple printing operations into a single printing pass on the integrated print carrier layer. This eliminates the need for multi-device coordination and alignment, as all decorative elements are applied in one operation.
6Ease of manufacture
If conventional coating is used, then the basic layer can be applied, but insufficient cohesion between layers causes delamination under stress
Solution Approach 1:
The patent uses a multi-layer composite structure where each layer has specific properties designed to work with adjacent layers. The combination of porous and non-porous layers, along with compatible material selections at each interface, creates strong inter-layer bonding that prevents delamination under stress.
Solution Approach 2:
The patent introduces intermediate layers with specific properties that mediate between adjacent layers with different characteristics. These intermediate layers provide compatible bonding surfaces for both neighboring layers, ensuring strong adhesion across the entire multi-layer 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
This method achieves improved image quality and resistance to delamination by forming a permeable basic layer that absorbs condensation products without impairing print quality, and reinforces cohesion between layers, reducing the need for special equipment.
Implementation Method 1
after evaporation of volatile components such as solvents, a coating with a porosity such that any condensation products such as water formed later on, upon curing of the ink or the subsequent layers may be adsorbed
Implementation Method 2
a coating with a porosity such that any condensation products such as water formed later on, upon curing of the ink or the subsequent layers may be adsorbed
Implementation Method 3
drying or curing the liquid ink forming the digitally printed decor
Implementation Method 4
coating the digitally printed decor with an overlay at conditions which ensure curing of both the basic layer and the overlay
Implementation Method 5
after curing, the composition reinforces cohesion between the decor and the substrate, thus acting as an adhesive and preventing delamination under stress
Data Source
Figure 1
AI summary
The present invention concerns a method for the manufacture of wood fiber or mineral fiber based decorative substrates (1), comprising the steps of: • (a) coating a substrate (2) with a liquid reactive composition which can be digitally printed on after drying; • (b) drying the reactive composition coated onto the substrate so as to form a basic layer (3) having a permeability such that it may adsorb and release any condensation products formed during step (d) and (e); • (c) digitally printing a decor (4) onto the basic layer using a liquid ink; • (d) drying or curing the liquid ink forming the digitally printed decor; and • (e) coating the digitally printed decor with an overlay (5) at conditions which ensure curing of both the basic layer and the overlay. The invention further concerns a floor panel or board (1) obtainable by a method according to the invention.