Decorative Substrate Manufacturing with Digital Foil Printing
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Solution Overview
Problem
Existing systems for applying decorative designs on substrates require frequent changes of foil spools to accommodate different designs, limiting versatility and flexibility in manufacturing.
Innovation Solution
A system incorporating digital printing means to print decorative designs directly on foils before coating, allowing for continuous or discontinuous foil feeding, and adaptive application of adhesive glue based on substrate features, enabling versatile and flexible manufacturing of substrates with varied designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If foil spools are changed to accommodate different decorative designs, then design variety is achieved, but manufacturing efficiency and productivity deteriorate due to frequent interruptions
Solution Approach 1:
The patent uses digital printing to create decorative designs directly on the foil surface, replacing the need for pre-printed foils and physical spool changes. The printing system copies desired decorative patterns onto the foil in real-time, maintaining continuous production while achieving design variety.
Solution Approach 2:
The system changes the decorative design parameters digitally through the printing system rather than physically changing foil spools. This allows instant transition between different decorative patterns while maintaining the same continuous foil feed, resolving the contradiction between design variety and manufacturing efficiency.
2Manufacturing precision
If pre-printed foils are used for each decorative design, then design precision is ensured, but device complexity and inventory requirements worsen
Solution Approach 1:
The patent extracts the decorative design function from the physical foil manufacturing process and relocates it to a digital printing system applied directly on the foil. This eliminates the need for maintaining inventories of pre-printed foils for different designs while ensuring design precision through digital control.
Solution Approach 2:
The digital printing system serves multiple functions: it can print any decorative design pattern, works with a single universal foil spool, and adapts to different substrate requirements. This multi-functionality replaces the need for multiple specialized pre-printed foil inventories.
3Ease of operation
If adhesive glue is applied uniformly to all substrates, then application simplicity is maintained, but manufacturing precision worsens due to inability to adapt to different substrate features
Solution Approach 1:
The system applies adhesive glue with locally adapted properties and quantities based on specific substrate features detected by scanning systems. Different areas of the substrate receive customized adhesive application parameters, achieving precision while maintaining automated operation through digital control.
Solution Approach 2:
The system incorporates scanning and sensing capabilities that detect substrate features and provide feedback to the adhesive application system. This closed-loop control enables precise adhesive application adapted to each substrate's specific characteristics while maintaining automated operation.
Data Source
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AI summary
The present invention relates to a system for manufacturing a substrate (1) with a decorative design (3), such as an image and/or a relief, which comprises feed means (10; 90) for feeding a foil (2), digital printing means (5, 40) for printing the decorative design (3) on the foil (2) and coating means (30; 50, 51) for coating the substrate (1) with the foil (2). The system is configured for printing the foil (2) with the digital printing device (5, 40) after supplying the foil (2) with the feed means (10; 90) and before coating the substrate (1) with the coating means (30; 50, 51).