Decorative Coating Patterning With Digital Resist Lacquer Printing
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Solution Overview
Problem
The existing screen printing method for applying resist lacquer on vehicle interior decorative and trim parts is labor-intensive, limited in graphic possibilities, and prone to inaccuracies, especially for large designs.
Innovation Solution
A method using digital printing machines to apply resist lacquer on decorative layers, allowing for precise and flexible creation of various patterns, including vector and pixel graphics, semi-tones, and color gradients, with the option to combine with haptic or roller printing, and subsequent milling or brushing for surface hatching, while enabling the use of metal sheets and protective coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If screen printing method is used for applying resist lacquer, then the process can be implemented with conventional equipment, but the preparation, storage, and cleaning effort increases significantly
Solution Approach 1:
The patent replaces the mechanical screen printing system with a digital printing system that uses digital files and automated print heads. This substitution eliminates the need for physical screens, their preparation, storage, and cleaning, while maintaining the ability to apply resist lacquer patterns to the decorative layer
Solution Approach 2:
The patent uses digital copies (digital files) of patterns instead of physical screens. The digital patterns can be stored, reproduced, and modified without physical handling, eliminating the time-consuming screen preparation and cleaning processes while maintaining pattern accuracy
2Ease of manufacture
If screen printing method is used for applying resist lacquer, then conventional equipment can be utilized, but graphic possibilities are limited
Solution Approach 1:
The patent introduces dynamic flexibility by using digital files that can be easily modified, scaled, and adapted. Unlike fixed screens, digital patterns can be changed rapidly to create different graphic designs, patterns, and layouts without requiring new physical screens, thus greatly expanding graphic possibilities
Solution Approach 2:
The digital printing system serves multiple functions: it can create various patterns, patterns with different resolutions, patterns of different sizes, and can be easily reconfigured for different products. This multi-functionality replaces the need for multiple specialized screens while maintaining ease of manufacture
3Ease of manufacture
If screen printing method is used for applying resist lacquer, then the process is established, but inaccuracies occur in fit for large screens
Solution Approach 1:
The patent replaces the mechanical screen system with a digital printing system that uses digital coordinates and automated positioning. This substitution eliminates dimensional distortions inherent in large physical screens while maintaining the established process workflow, achieving superior fit accuracy for large-area applications
Data Source
AI summary
A method of producing a molded part comprising a decorative coating with a molded part front side designed as visible side and a rear side opposing the front side and a substrate arranged on the rear side of the decorative coating, wherein the decorative coating comprises (or is formed from) a decorative layer, wherein the method comprises: providing the decorative layer or decorative coating, attaching the substrate to the rear side of the decorative layer or coating, applying a resist lacquer to the front side of the decorative layer by means of a digital printing machine, the resist lacquer being applied in sections to the front side of the decorative layer to form a pattern or symbol or a negative of a pattern or symbol such that lacquer-free surface areas and surface areas covered with resist lacquer are created on the front side of the decorative layer.