Two-Layer Inkjet Receiver Coating for Dust-Reduced Decor Paper
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Solution Overview
Problem
Existing methods for manufacturing decorative panels using digital inkjet printing face challenges such as high dust release, uneven ink application, and printing defects, particularly when integrating inkjet receiver coatings, leading to production inefficiencies and quality issues.
Innovation Solution
Applying an inkjet receiver coating in two partial steps, with distinct compositions for each layer, to enhance pigment binding and uniformity, reducing dust release and improving ink absorption, thereby stabilizing the paper for further processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an inkjet receiver coating is applied to improve ink absorption and printing quality, then printing quality is improved, but dust release increases
Solution Approach 1:
The inkjet receiver coating is divided into two distinct layers: a first layer applied to the paper providing ink absorption properties, and a second layer applied over the first layer providing a dust-reducing surface. This segmentation allows each layer to perform its specific function optimally without compromising the other.
2Productivity
If analog printing processes are used to print decor patterns, then printing flexibility is restricted, but production costs are reduced
Solution Approach 1:
The patent uses an intermediary carrier layer (the printed paper with decor pattern) that can be produced using cost-effective analog printing processes, then transferred to the final substrate. This intermediary approach allows the use of cheaper printing methods while still achieving the flexibility of digital printing by changing the decor on the carrier layer.
3Adaptability or versatility
If resin is provided on paper before printing, then printing flexibility is improved, but paper expansion becomes difficult to control
Solution Approach 1:
The paper is pre-treated with an inkjet receiver coating before printing and resin application. This preliminary action prepares the paper surface to control resin absorption and prevent uncontrolled expansion during subsequent processing steps.
4Adaptability or versatility
If digital inkjet printing is used to enhance printing flexibility, then production efficiency decreases, but printing quality improves
Solution Approach 1:
The patent merges the advantages of both analog and digital printing by using digital inkjet printing to apply the inkjet receiver coating and decor patterns on a carrier layer, then transferring this pre-printed layer to the final substrate. This combining approach maintains the flexibility of digital printing while improving overall production efficiency through batch processing.
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 two-step inkjet receiver coating method significantly reduces dust release, ensures even ink application, and enhances printing quality, allowing for more efficient and stable production of decorative panels.
Implementation Method 1
coating at least one side of said paper layer with an inkjet receiver coating comprising pigment and binder
Implementation Method 2
enhance pigment binding
Implementation Method 3
inkjet receiver coating comprising pigment and binder
Data Source
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AI summary
Method for manufacturing paper or thermoplastic foil printable with an inkjet printer for use as a decor paper, respectively decor foil in a laminate or laminated panel, wherein the method at least comprises the following steps: - the step of providing a paper layer (1), respectively a thermoplastic foil; - the step of coating at least one side of said paper layer, respectively said foil with an inkjet receiver coating (3) comprising pigment (6) and binder (7); characterized in that said inkjet receiver coating is applied in at least two partial steps, wherein respectively a first layer (4) with a first composition and, subsequently, a second layer (5) is applied with a second composition, both compositions at least comprising said binder. The invention also relates to the papers and foils obtained, as well as to method of manufacturing panels wherein the paper or foil is provided with a printed pattern and use as a decor in the panels.