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Mass-customization is a megatrend that also affects the wood industry. To obtain individually designed laminates in batch size one efficient printing and processing technologies are required. Digital printing was envisaged as it does not depend on highly costly printing cylinders (as used in rotogravure printing) and allows rapid exchange of the printing designs. In the present work, two wellestablished digital printing approaches, the multi-pass and the single-pass technique, were investigated and evaluated for their applicability in decorating engineered wood and low-pressure melamine films. Three different possibilities of implementing digital printing in the decorative laminates manufacturing process were studied: (1) digital printing on coated chipboard and subsequently applying a lacquered top-coat or melamine overlay (designated as “direct printing”, since the LPM was the printing substrate), (2) digital printing on decorative paper which was subsequently impregnated before hot pressing (designated as “indirect printing, variant A”) and (3) digital printing on decorative paper with subsequent interlamination of the paper between impregnated under- and overlay paper layers during the pressing process (designated as “indirect printing, variant B”). Due to various advantages of the resulting cured melamine resin surfaces including a much better technological performance and flexibility in surface texture design, it was decided to industrially further pursue only the indirect digital printing process comprising interlamination and the direct printing process with a melamine overlay-finishing. Basis for the successful trials on production and laboratory scales were the identification of applicable inks (in terms of compatibility with melamine resin) and of appropriate printing paper quality (in terms of impregnation and imprinting ability). After selection and fine tuning of suitable materials, the next challenge to overcome was the initially insufficient bond strength between impregnated overlay and the ink layers which led to unsatisfactory quality of the print appearance and delamination effects. However, the optimization of the pressing program and the development of a modified impregnation procedure for the underlay and overlay papers allowed the successful implementation of digital printing in the production line of our industrial partner FunderMax.
Melamine formaldehyde (MF) resins are widely used for the gluing and surface coating of wood-based consumer products in the interior design of living environments. MF resins are especially relevant in decorative laminate applications because of their good performance-to-price ratio. In their industrial processing, an important intermediate state is the liquid MF prepolymer that is used for decorative paper impregnation. Here, the drying of impregnated papers is investigated with respect to premature curing. A new method to quantify water release upon drying that allows estimation of the degree of undesired precuring is described. Since curing proceeds via polycondensation, crosslinking brings about the release of water molecules. By thermogravimetric analysis (TGA), drying was studied in terms of water release due to physical drying (elimination of “dilution water”) and chemical crosslinking of the prepolymer to a three-dimensional MF network (elimination of chemically liberated water). The results obtained by TGA/IR spectroscopic analysis of the liberated volatiles show that the emission of water from b-stage MF can be clearly analytically separated into a physical (evaporation of dilution water) and a chemical (liberation via condensation) sequence. TGA experiments were correlated with curing experiments performed with differential scanning calorimetry (DSC) to estimate the residual crosslinking capacities of the impregnated papers. The drying conditions used during the preparation of impregnated decorative papers seemed to significantly affect their remaining reactivity only when harsh drying conditions were used. Upon heat exposure for prolonged time, precuring of the oligomer units results in a shift of the temperature maxima in TGA.
