Pre-impregnated foils are a cost-effective solution for achieving the desired surface resistance and closedness without the need for expensive high-density laminates. These foils are commonly used for cabinet interiors, sides, as well as in the production of furniture for first homes, kids, and youth.

Unlike decor papers, pre-impregnated foils are not fully impregnated. This means that the quality requirements for these foils are not as extreme. Additionally, the final shade can be seen shortly after production, reducing the time-consuming process of color adjustments often associated with decor papers.

The shades of pre-impregnated foils primarily consist of various shades of white, or brown for printing wood textures on the paper. When imitating wood finishes, the foils are printed using offset or screen printing techniques, allowing for a three-dimensional effect to be achieved.

The basis weight range for these foils typically falls between 80-120 g/m2. However, there is a thicker variation, ranging from 200-400 g/m2, which is specifically used for covering the edges of panes. The furnish used in the production of these foils is a mixture of hardwood and softwood, optimizing runnability and formation. Inorganic pigments, particularly iron oxides, are utilized for coloring purposes.

Impregnation of the foils can be done on the paper machine using a modified size press. The resins used for impregnation come in different types, depending on the required degree of stiffness for the foil’s application. A stiffer foil provides better coverage of the underlying particle board pane’s structure, but it is also more brittle and delicate to handle.

One significant challenge in the production of pre-impregnated foils has been the emission of noxious formaldehyde gases during the curing of the resins used. However, this issue has been partially addressed by utilizing low formaldehyde melamines or ureic resins.

In conclusion, pre-impregnated foils offer a cost-effective alternative to high-density laminates for achieving surface resistance and closedness. With various shades available and the ability to imitate wood finishes, these foils are suitable for a range of applications in the furniture industry. Despite some challenges, such as formaldehyde emissions, advancements in resin technology have helped mitigate these issues and make pre-impregnated foils a viable solution for many manufacturers.