UV-Curable Polymer Impregnation for Decorated Sheets
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Solution Overview
Problem
The existing methods for producing decorative laminates require separate production steps for printing and impregnation of decorative paper, which are costly and result in dimensional changes, water sensitivity, loss of flexibility, and incompatibility with varnish or synthetic resin, making it difficult to maintain the spatial relationship between the decor and surface structure.
Innovation Solution
A method using an aqueous dispersion of a polymer cross-linkable by UV radiation for impregnating cellulose non-woven fabrics, which is compatible with aminoplast resins, maintains dimensional stability, provides complete water resistance, and allows for flexible storage and handling, with the option to print before or after impregnation, and subsequent curing by UV irradiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If decorative paper is impregnated with traditional varnish or synthetic resin, then the decorative laminate can be produced, but the paper undergoes dimensional change and loses flexibility
Solution Approach 1:
The patent changes the chemical parameters of the impregnating material by using an aqueous dispersion of a polymer cross-linkable by UV radiation instead of traditional varnish or synthetic resin. This parameter change allows the paper to maintain dimensional stability while preserving flexibility, as the UV-curable polymer system does not cause the same dimensional changes as traditional impregnating materials.
Solution Approach 2:
The patent replaces the traditional mechanical impregnation process with a UV-curable polymer system that cures upon exposure to UV radiation. This substitution eliminates the need for complex impregnation equipment and reduces the number of production steps while maintaining the protective function of the decorative laminate.
2Manufacturing precision
If separate production steps for printing and impregnation are used, then decorative paper can be produced, but production cost increases and process complexity increases
Solution Approach 1:
The patent merges the printing and impregnation processes into a single integrated step. The decorative paper is printed and then immediately impregnated with the UV-curable polymer dispersion in one continuous operation, eliminating the need for separate production steps and reducing overall process complexity while maintaining print quality.
Solution Approach 2:
The patent applies the impregnating polymer dispersion to the printed paper before the paper undergoes any dimensional changes or processing. This preliminary action ensures that the polymer penetrates the paper uniformly and maintains the spatial relationship between the decor and the surface structure, while also simplifying the production process by combining multiple steps into one.
3Reliability
If traditional impregnation materials are used, then decorative laminate can be produced, but water resistance is compromised and sensitivity to penetrating water occurs
Solution Approach 1:
The patent changes the chemical composition of the impregnating material to an aqueous dispersion of UV-curable polymer, which forms a water-resistant barrier when cured. This parameter change provides complete water resistance while maintaining compatibility with aminoplast resins used in other laminate layers, eliminating the water sensitivity problem of traditional impregnation materials.
Solution Approach 2:
The patent uses a composite impregnation system combining aqueous polymer dispersion with UV curing agents and aminoplast resins. This composite material system provides both water resistance and chemical compatibility with other laminate components, creating a multi-functional protective layer that addresses both water resistance and chemical compatibility requirements.
4Reliability
If decorative paper is impregnated with aminoplast, then decorative laminate can be produced, but the paper becomes sensitive to penetrating water and requires sealing at side edges
Solution Approach 1:
The patent changes the impregnation material from aminoplast to UV-curable polymer dispersion, which cures to form a water-resistant barrier. This parameter change eliminates the need for additional sealing at side edges while maintaining compatibility with aminoplast resins used in other laminate layers, providing both water resistance and production feasibility.
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 the production process, reduces ink usage, enhances print clarity, maintains the spatial relationship between decor and surface structure, and allows for flexible storage and handling of the decorated sheets, while ensuring complete water resistance and compatibility with other laminate resins.
Implementation Method 1
an aqueous dispersion of a polymer cross-linkable by UV radiation... subsequent curing by UV irradiation
Data Source
AI summary
Decorated sheets on the basis of cellulose non-woven fabrics, such as paper, for the production of decorated laminates are impregnated with synthetic resins. Consequently, their sizes are changed, they become brittle and are not water-resistant in the laminate. In the method according to the invention the printed or unprinted non-woven fabrics are impregnated with an aqueous dispersion of a polymer which is cross-linkable by UV radiation, dried and optionally printed and finally irradiated with UV radiation. The decorated sheets thus obtained are water-resistant in the laminate and can be coiled up and stored after each process step.