Resin-Coated Underlayer for Printable Semifinished Product Bonding
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Solution Overview
Problem
The production of partially resin-coated printing paper is costly and requires significant equipment, making it difficult to achieve precise resin application, especially for small quantities, and may not ensure a permanent connection to a base body during pressing.
Innovation Solution
A method using a resin-coated underlayer ensures a secure connection to the base body regardless of printing paper type or thickness, allowing for either full or partial resination of the printing paper layer, with the upper side remaining resin-free, and enabling direct ink application without blotting, using a short-cycle pressing method with controlled pressure, temperature, and resin properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If partially resinated printing paper is produced using conventional methods, then printing quality can be improved, but equipment costs and production complexity increase significantly
Solution Approach 1:
The printing paper is divided into two distinct layers: a resin-free upper layer for optimal printing quality and a resin-coated lower layer for secure bonding. This segmentation allows each layer to perform its specific function without compromising the other, achieving both high printing quality and reliable adhesion without complex equipment
Solution Approach 2:
The resin coating function is extracted from the entire printing paper and applied only to the lower layer. This extraction eliminates the need for complex partial resination equipment while maintaining the benefits of resin coating where needed, simplifying the overall production process
2Manufacturing precision
If partial resination is achieved for different paper thicknesses, then printing quality and adhesion can be optimized, but process parameter complexity and costs increase
Solution Approach 1:
By segmenting the paper into upper and lower layers with different resin treatments, the invention eliminates the need to adjust process parameters for different thicknesses. The lower layer consistently receives resin coating while the upper layer remains resin-free, providing uniform results across various paper types without complex parameter adjustment
Solution Approach 2:
The invention changes the approach from controlling resin application parameters across the entire paper to a binary parameter system: the lower layer receives resin coating while the upper layer does not. This parameter change simplifies the manufacturing process for different paper thicknesses
3Reliability
If resin coating is applied to ensure permanent connection, then adhesion reliability improves, but printing quality may deteriorate due to resin interference
Solution Approach 1:
The paper is segmented into resin-free upper layer for printing and resin-coated lower layer for bonding. This segmentation ensures that resin is present only where needed for adhesion, while the printing surface remains completely free of resin interference, maintaining both connection permanence and printing quality
Solution Approach 2:
Different regions of the paper are given different qualities: the upper layer is kept resin-free to maintain printing quality, while the lower layer is resin-coated to ensure connection permanence. This local differentiation of material properties resolves the contradiction between adhesion and printability
4Ease of manufacture
If small quantities of printing paper are produced, then equipment costs for partial resination become prohibitively high, but production flexibility is reduced
Solution Approach 1:
Segmenting the paper into differently treated layers allows for simple, cost-effective production of small quantities. The resin-free upper layer and resin-coated lower layer can be produced using basic equipment, making small-batch production economically viable while maintaining flexibility
Solution Approach 2:
The invention uses a simple, cost-effective structure where the printing paper with its differentiated layers can be produced without expensive equipment. This approach is particularly advantageous for small quantities, making the process economically viable for limited production runs
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 simplifies and cost-reduces the production of semi-finished products, ensuring a secure connection and optimal printing results by controlling resin distribution and preventing ink runoff, allowing for subsequent processing or storage before printing.
Implementation Method 1
a resin-coated underlayer (5) which is arranged between the printing paper layer (4) and the base body (3) and which is pressed together with the printing paper layer (4) to the base body (3)
Implementation Method 2
a secure connection of the printing paper to the base body can be ensured in any case after pressing
Implementation Method 3
using a short-cycle pressing method with controlled pressure, temperature, and resin properties
Implementation Method 4
using a short-cycle pressing method with controlled pressure, temperature, and resin properties
Data Source
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AI summary
The invention relates to a method for the production of a planar, printable semifinished product (1) for a planar building component (2), particularly for floor, wall, ceiling, and/or furniture uses, wherein a printable, unprinted printing paper layer (4) is pressed under the influence of pressure and heat together with a planar base body (3). According to the invention, a lower layer (5) covered with resin is arranged on the base body (3) before the pressing. Said lower layer (5) is located between the base body (3) and the printing paper layer (4), and the lower layer (5) together with the printing paper layer (4) is pressed to the base body (3).