Decorative Sheet Texture Alignment via Selective UV Curing

The patent combines the decorative motif printing and the texture-defining mask printing into a single integrated printing step. The printing plate directly prints both the decorative motif and the corresponding mask pattern in one operation, eliminating the need for separate printing steps and complex register steering mechanisms. This resolves the alignment problem caused by substrate shrinkage and expansion between multiple printing operations.

The printing plate is segmented into different functional zones: areas with decorative motif patterns that define where texture should appear, and corresponding mask patterns that control UV light transmission. This segmentation allows the single printing step to simultaneously define both the decorative appearance and the texture locations, simplifying the overall process while maintaining precise alignment.

The patent replaces the mechanical embossing system with a UV light-based system. Instead of using mechanical pressure and heat to create textures through embossing and fusing, the invention uses selective UV light transmission through a printed mask to cure the top coating only in specific areas. This substitution eliminates multiple mechanical steps (embossing, fusing) while achieving the same texture differentiation effect, reducing process complexity and cost.

The patent utilizes the phase transition of the UV-curable top coating material from uncured to cured state through selective UV light exposure. Areas where UV light passes through the mask are cured and form textured surfaces, while areas blocked by the mask remain uncured and are later removed or remain smooth. This phase transition mechanism replaces complex mechanical embossing processes with a simpler photopolymerization process.