Digital Embossed Surface Coverings With Spacer-Layer 3D Relief

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Solution Overview

Problem

Existing decorative surface coverings, particularly those with digitally printed décors, lack the ability to effectively create three-dimensional surface reliefs that enhance the realism of the printed designs, and existing embossing methods are limited in flexibility and precision.

Innovation Solution

A method involving digital embossing techniques to generate a three-dimensional surface relief at a controlled distance from the décor layer using a transparent or translucent spacer layer, combined with digital 3D printing or additive techniques to create a three-dimensional surface texture in register with the two-dimensional décor, utilizing various embossing agents and coatings to control the pattern of the spacer layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If mechanical embossing is used to create three-dimensional surface relief, then the realism of the printed décor is improved, but the production cost and process complexity increase

Engineering Contradiction:

Improverealism of printed décorVSAvoidembossing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent uses a digital model to create a three-dimensional surface relief that copies the desired pattern. Instead of using complex mechanical embossing plates, the invention digitally models the relief and applies it through coating and selective removal processes, simplifying the manufacturing apparatus while maintaining high realism of the décor pattern

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the traditional mechanical embossing system with a digital modeling and selective coating removal system. Instead of using mechanical pressure and embossing plates, the invention uses digital design software to create the relief pattern and applies coating material that is then selectively removed to reveal the three-dimensional effect, thereby reducing mechanical complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Shape

If traditional embossing plates are used, then three-dimensional relief is achieved, but the flexibility to change designs is reduced

Engineering Contradiction:

Improvethree-dimensional reliefVSAvoiddesign flexibility

Core Design Contradiction:

ShapeVSAdaptability or versatility

Solution Approach 1:

The patent makes the embossing system dynamic by using digital modeling instead of fixed mechanical plates. The three-dimensional relief pattern is defined by digital data that can be easily modified and updated, allowing rapid design changes without requiring new physical embossing plates. This dynamic approach enables flexibility in changing designs while maintaining the three-dimensional relief effect

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent allows for easy modification of design parameters in the digital model. By changing the digital data that defines the three-dimensional relief pattern, different designs can be created without physical retooling. This parameter-based control provides adaptability and versatility in design changes while maintaining the desired three-dimensional shape

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If high-quality embossing is applied in register with printed décor, then the appearance realism is enhanced, but the manufacturing precision requirements increase

Engineering Contradiction:

Improveregister alignment between embossing and printVSAvoidregistration system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent uses a universal reference system based on digital data that serves multiple functions. The same digital model that defines the three-dimensional relief pattern also provides registration information for aligning the embossing with the printed décor. This multi-functional digital approach simplifies the registration process while maintaining high alignment precision, eliminating the need for separate complex mechanical registration systems

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12629960B2Digital embossing of decorative surface coverings

Publication Date: 2026.05.19 TARKETT GDL

AI summary

A method for producing a decorative surface covering comprises providing a structural core, including one or more core layers, the structural core carrying a décor layer representing a two-dimensional décor, and generating a three-dimensional surface relief by digitally embossing, in register with the two-dimensional décor, where the three-dimensional surface relief is generated at a distance of at least 0.1 mm from the décor layer by applying a transparent or at least translucent spacer layer against the décor layer, the spacer layer having a thickness that remains unmodified by the digital embossing and that corresponds to the distance, and where the three-dimensional surface relief is generated in one or more coating layers on a side of the spacer layer facing away from the décor layer after application of the spacer layer against the décor layer.