Method for manufacturing three-dimensional texture structure on surface of substrate

Abstract

A method for manufacturing a three-dimensional texture structure on the surface of a substrate (4), comprising: step 1, preparing at least one digital exposure device (1), connecting same to a computer, and importing a texture pattern into the digital exposure device (1) by means of corresponding software in the computer, for later use; step 2, preparing a substrate (4), processing a coating (5) on the surface of the substrate (4), and placing the substrate (4) under the digital exposure device (1) to await curing; step 3, awaiting curing of the coated substrate (4), and starting the digital exposure device (1), to implement exposure and curing; step 4, transferring the substrate (4), a portion of the coating (5) of which has been cured, to a removal workstation, and, by means of a removal mechanism (6), removing the coating (5) which has not been not cured on the surface of the substrate (4), so as to obtain a sheet having a cured three-dimensional texture structure on the surface. The method has the following effects: 1. greatly improved visual and tactile effects; 2. greatly reduced difficulty of a pattern registration process; 3. high precision of synchronization between a pattern in an image and the texture; and 4. a mold does not need to be manufactured or replaced, and costs are low.

Description

A method for manufacturing a three-dimensional texture structure on a substrate surface Technical Field

[0001] The present invention relates to the technical field of plate processing, and in particular to a method for manufacturing a three-dimensional texture structure on the surface of a substrate through a novel process. Background Art

[0002] The architectural decoration industry is in high demand for materials like wood and stone. However, due to limited natural resources, most current architectural decoration materials are printed to mimic natural materials like wood and stone. These materials are then combined with a variety of substrates (such as wood (particleboard, medium-density fiber "MDF"), high-density fiber "HDF"), or plywood), plastics (such as PVC, PET, and PP), cellulose-based materials (paper or cardboard), and metals). This approach conserves natural resources while meeting market demands. Because printed wood and stone grains can only achieve color simulations, a synchronized patterning process is required to synchronize the color and texture, ultimately creating a realistic visual and tactile effect. This synchronized patterning process has always been a major challenge in the production of decorative materials. Currently, texture is achieved through embossing: a embossed pattern is first engraved on a steel plate or roller-type mold. The mold is then placed on the substrate and, using pressure, the texture from the mold is transferred to the substrate surface. This method has many disadvantages, such as: the texture length is limited due to mold size restrictions; the texture design is single and difficult to synchronize; the more texture designs, the higher the mold cost; changing molds during production affects production capacity, etc.

[0003] Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, the present invention aims to provide a method for manufacturing a three-dimensional texture structure on the surface of a substrate.

[0005] To achieve the above object, the technical solution adopted by the present invention is:

[0006] A method for producing a three-dimensional texture structure on a substrate surface, comprising:

[0007] Step 1: Prepare at least one digital exposure device and connect it to a computer, and import the processed texture pattern into the digital exposure device through the corresponding software in the computer for standby use;

[0008] Step 2: Prepare a substrate with an imaging pattern on its surface, apply a layer of UV coating on the surface to form a coating, and place the coated substrate under a digital exposure device to wait for curing;

[0009] Step 3: The coated substrate is transported by an automatic conveyor to the exposure station to wait for curing. The digital exposure device is started, which emits light according to the pre-imported pattern file, forming an exposure projection area on the substrate surface. The UV coating in the projection area undergoes a cross-linking reaction under the action of light, thereby achieving exposure curing.

[0010] Step 4: The substrate with partially cured coating is transferred to a cleaning station, and the uncured coating on the surface of the substrate is removed by a cleaning mechanism to obtain a plate with a cured three-dimensional texture structure on the surface.

[0011] The method further includes step 5, transferring the plate obtained in step 4 to a drying device to remove residual moisture on the surface of the substrate; and step 6, transferring the dried plate to a radiation irradiation area to reinforce the solidified three-dimensional texture structure; the radiation area is irradiated using a mercury lamp.

[0012] Furthermore, the main body of the digital exposure device is a DLP optical machine, and the number of the DLP optical machine is determined by the width of the substrate and the production capacity requirement. According to the demand, multiple digital exposure devices are spliced ​​together to perform exposure operations simultaneously.

[0013] Furthermore, in step 2, the coating is formed by coating the surface of the substrate.

[0014] Furthermore, in step 3, the wavelength of the light emitted by the digital exposure device is 320-700 nm, and the curing time is 0.1-180 s.

[0015] Furthermore, in step 3, the projection mode of the digital exposure device is a static mode or a dynamic mode.

[0016] Furthermore, when the digital exposure device uses a static mode light machine, the shadow range it projects is fixed.

[0017] Furthermore, when the digital exposure device uses a dynamic mode light machine, the pattern projected by the digital exposure device is dynamic and continuous.

[0018] Furthermore, in step 3, the curing power of the digital exposure equipment is 1-120W, and the curing speed is 1-500mm / s.

[0019] Furthermore, in step 4, the cleaning method is a physical method, including any one of high-pressure water flushing and high-pressure air.

[0020] Technical Effects: The method of the present invention utilizes DLP digital light processing technology to locally UV-cure a coating applied to a substrate surface and remove the uncured portion, thereby forming a three-dimensional texture on the surface. Compared to existing similar processes, the method of the present invention has the following benefits: 1. Each image has a corresponding and unique three-dimensional texture, significantly improving visual and tactile effects; 2. It facilitates shortening the process flow and significantly reduces the difficulty of synchronous pattern alignment; 3. It allows for rapid and precise positioning of the work position, achieving high-precision synchronization between image and texture; 4. It eliminates the need for mold production or replacement, resulting in low costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] FIG1 is a schematic diagram showing the connection of a DLP optical engine and related modules according to an embodiment of the present invention;

[0022] FIG2 is a schematic diagram showing the principle of forming a three-dimensional structure texture according to an embodiment of the present invention;

[0023] FIG3 is a schematic diagram of the processing of step 2 according to an embodiment of the present invention;

[0024] FIG4 is a schematic diagram of the processing of step 3 according to an embodiment of the present invention;

[0025] FIG5 is a schematic diagram of the processing of step 4 according to an embodiment of the present invention;

[0026] FIG6 is a processing schematic diagram of step 5 according to an embodiment of the present invention. DETAILED DESCRIPTION

[0027] In order to enable those skilled in the art to better understand the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and implementation methods.

[0028] As shown in Figures 1-2, an embodiment of the present invention provides a method for manufacturing a three-dimensional texture structure on the surface of a substrate, which is a process of synchronously aligning patterns through a digital exposure device. Specifically, the main body of the digital exposure device 1 is a DLP optical machine, that is, the present invention adopts DLP digital light processing technology and is completed by a commercially available DLP optical machine. The DLP optical machine is connected to a main light source 2, and is also provided with a light source 3 connected to the main light source and hardware such as a power supply. The basic principle is to prepare a surface plate-like substrate 4, and apply a layer of liquid (usually UV paint) on its surface to form a coating 5, and then partially cure the coating 5 through the light projected by the DLP optical machine lens. After the curing is completed, the uncured area is removed, and a three-dimensional structural texture can be obtained on the surface of the substrate; as shown in Figure 2. The method specifically includes the following steps:

[0029] Step 1: Prepare at least one digital exposure device (i.e., DLP light machine) and connect it to a computer. Use the corresponding software in the computer to import the processed texture pattern into the digital exposure device for standby use.

[0030] Step 2: Prepare a plate-shaped substrate 4 having an imaging pattern on its surface. In this embodiment, the coating is formed by coating the substrate surface. For example, a single-roll or double-roll coater is used to apply a layer of UV coating to the substrate surface to form a coating 5. The coated substrate is then placed under a digital exposure device to wait for curing, as shown in FIG3 .

[0031] Step 3: The coated substrate is transported by an automatic conveyor to an exposure station to wait for curing; the digital exposure device 1 is started, which emits light according to the pre-input pattern file, forming an exposure projection area on the substrate surface. The UV coating layer 5 in the projection area undergoes a cross-linking reaction under the action of light, thereby achieving exposure curing; as shown in Figure 4;

[0032] Step 4: The substrate 4 with partially cured coating is transferred to a cleaning station, and the uncured coating on the substrate surface is removed by a cleaning mechanism 6 to obtain a plate with a cured three-dimensional texture structure on the surface; as shown in FIG5 .

[0033] In this embodiment, to dry the substrate surface and strengthen the three-dimensional texture structure on the substrate surface, the process further includes step 5, transferring the plate obtained in step 4 to a drying device to remove residual moisture from the substrate surface; and step 6, transferring the dried plate to a radiation irradiation area to strengthen the solidified three-dimensional texture structure. The irradiation area is irradiated by a mercury lamp 7, as shown in Figure 6. Drying can be performed using either ambient air drying or high-temperature drying, with the high-temperature drying temperature being 60°-100°C and the drying speed being 10-30 m / s.

[0034] Specifically, in steps 1-3, the number of the digital exposure devices 1 is determined by the width of the substrate and the production capacity requirements. According to the needs, multiple DLP light machines are spliced ​​together to perform exposure operations at the same time. The multiple here should be understood as more than two. Connecting the automation equipment (digital exposure equipment) to the computer (i.e., PC terminal) and installing special software on the computer for control belongs to the existing common technology and will not be described in detail here. The imaging pattern on the surface of the substrate can be processed and produced by digital printing, film lamination, etc.; for example, for wood grain flooring, the wood grain pattern can be first printed on a board using digital printing (i.e., to produce a shading of a three-dimensional texture structure), and then UV paint is applied on the shading to form a coating. Specifically, in step 2, the surface of the substrate can be coated by printing, pressing, flat lamination, transfer, etc.; specifically, this embodiment uses a single-roller or double-roller coater to coat a layer of UV paint material on the surface of the substrate.

[0035] Specifically, in step 3, the wavelength of the light emitted by the digital exposure device is 320-700 nm, and the curing time is 0.1-180 s; preferably, the wavelength is 320 nm.

[0036] Specifically, in step 3, the projection mode of the digital exposure device 1 is a static mode or a dynamic mode.

[0037] Specifically, when the digital exposure device 1 selects the static mode, the shadow range projected by it is fixed.

[0038] Specifically, when the digital exposure device 1 uses the dynamic mode, the pattern projected by the digital exposure device is dynamic and continuous. The digital exposure device 1 of this embodiment uses the dynamic mode, as shown in FIG4 .

[0039] Specifically, the curing power of the digital exposure device 1 is 1-120W, and the speed is 1-500mm / s; preferably, the curing power is 120W.

[0040] Specifically, in step 4, the cleaning method is a physical method, including a cleaning mechanism 6 made of any one of high-pressure water flushing, high-pressure air and a metal brush, that is, it is determined according to the actual situation whether to use high-pressure water flushing to remove the uncured coating or to directly use high-pressure air to blow off the uncured coating, or to brush off the uncured coating with a metal brush; as shown in Figure 5.

[0041] In summary, the method of the present invention adopts DLP digital light processing technology to project and solidify the area of ​​specific graphics; adopts a multi-wavelength light source, and adjusts the output ratio of each wavelength to connect to the optical machine through optical fiber coupling, so as to achieve an efficient curing effect; by removing the liquid in the uncured part, a three-dimensional structure texture effect is finally formed on the surface.

[0042] In the above description, it should be noted that the terms "installed", "connected", "connected" and other corresponding terms should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection, an indirect connection through an intermediate medium, or it can be a communication between the internal parts of two components.

[0043] Obviously, the embodiments described above are only some of the embodiments of the present invention, not all of them. The drawings provide preferred embodiments of the present invention, but do not limit the scope of the present invention. The present invention can be implemented in many different forms. On the contrary, the purpose of providing these embodiments is to make the understanding of the disclosure of the present invention more thorough and comprehensive. Any equivalent structure made by using the contents of the present description and drawings, directly or indirectly applied to other related technical fields, is also within the scope of protection of the present invention.

Claims

1. A method for producing a three-dimensional texture structure on a substrate surface, characterized in that: include: Step 1; Prepare at least one digital exposure device and connect it to a computer, and import the processed texture pattern into the digital exposure device through the corresponding software in the computer for standby use; Step 2: Prepare a substrate with a pattern on its surface, apply a layer of UV coating on the surface to form a coating, and place the coated substrate under a digital exposure device to wait for curing; Step 3: The coated substrate is transported by an automatic conveyor to the exposure station to wait for curing; The digital exposure device is started, which emits light according to the pre-imported pattern file, forming an exposure projection area on the substrate surface. The UV coating in the projection area undergoes a cross-linking reaction under the action of light, thereby achieving exposure curing; Step 4: The substrate with partially cured coating is transferred to a cleaning station, and the uncured coating on the surface of the substrate is removed by a cleaning mechanism to obtain a plate with a cured three-dimensional texture structure on the surface.

2. The method for producing a three-dimensional texture structure on a substrate surface according to claim 1, wherein: The method further includes step 5, transferring the plate obtained in step 4 to a drying device to remove residual moisture on the surface of the substrate; and step 6, transferring the dried plate to a radiation irradiation area to reinforce the solidified three-dimensional texture structure; the radiation area is irradiated using a mercury lamp.

3. The method for producing a three-dimensional texture structure on a substrate surface according to claim 1, wherein: In steps 1-3, the main body of the digital exposure device is a DLP light machine, and its number is determined by the width of the substrate and the production capacity requirements. According to demand, multiple digital exposure devices are spliced ​​together to perform exposure operations simultaneously.

4. The method for producing a three-dimensional texture structure on a substrate surface according to claim 1, wherein: In step 2, the coating layer is formed by coating the surface of the substrate.

5. The method for producing a three-dimensional texture structure on a substrate surface according to claim 1, wherein: In step 3, the wavelength of light emitted by the digital exposure device is 320-700 nm, and the curing time is 0.1-180 s.

6. The method for producing a three-dimensional texture structure on a substrate surface according to claim 1, wherein: In step 3, the projection mode of the digital exposure device is a static mode or a dynamic mode.

7. The method for producing a three-dimensional texture structure on a substrate surface according to claim 6, wherein: When the digital exposure device uses a static mode light machine, the shadow range it projects is fixed.

8. The method for producing a three-dimensional texture structure on a substrate surface according to claim 6, wherein: When the digital exposure device uses a dynamic mode light machine, the pattern projected by the digital exposure device is dynamic and continuous.

9. The method for producing a three-dimensional texture structure on a substrate surface according to claim 1, wherein: In step 3, the curing power of the digital exposure equipment is 1-120W and the speed is 1-500mm / s.

10. The method for producing a three-dimensional texture structure on a substrate surface according to claim 1, wherein: In step 4, the cleaning method is a physical method, including any one of high-pressure water flushing, high-pressure air, and a metal brush.

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