Digital Embossed In Register Surface Using Curable Ink Matrix
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Solution Overview
Problem
Current methods for producing embossed surfaces in building panels, such as laminate and powder-based floors, are costly and inflexible, often requiring expensive embossed steel plates or rollers, and result in repetition effects due to the need for identical embossed structures across all panels, limiting design variability and increasing production complexity.
Innovation Solution
A method involving digitally applied curable ink, forming an ink matrix that is pressed against the surface to create embossed structures, allowing for variable embossing in register with digital prints, enabling flexible and cost-efficient production of unique embossed designs on each panel without repetition effects, using UV curing polymers and a Piezo digital ink head.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional embossed steel plates or rollers are used to create embossed surfaces, then the surface structure is consistent and durable, but the production cost increases and design variability is limited due to repetition effects
Solution Approach 1:
The invention changes the physical state of the embossing tool from a rigid steel plate to a temperature-responsive material that transitions between solid and liquid states. This allows the embossing pattern to be dynamically changed by controlling temperature, enabling design variability without complex mechanical changes to the production line.
Solution Approach 2:
The embossing tool is made dynamic through temperature control, allowing it to change its embossing pattern on demand. The system transitions from static embossing plates to a dynamic system where the embossing pattern can be adjusted by changing the temperature state of the material, eliminating repetition effects while maintaining production efficiency.
2Reliability
If expensive embossed steel plates are used for surface embossing, then the embossed structure is durable and consistent, but the production cost increases
Solution Approach 1:
The invention replaces expensive, durable steel embossing plates with a cheaper, temperature-responsive material that can be repeatedly melted and reformed. The material is applied as a liquid or semi-liquid state, cured to form the embossed pattern, and then reused by melting and reapplying, eliminating the need for costly steel plates while maintaining consistency through controlled temperature processes.
Solution Approach 2:
By changing the temperature parameter of the embossing material, the system achieves both consistency and cost-effectiveness. The material is maintained at a controlled temperature to ensure proper curing and pattern formation, then heated to melt for reuse. This parameter control ensures reliable embossed structures without the need for expensive steel plates.
3Productivity
If identical embossed structures are applied to all panels, then the production process is simple and efficient, but repetition effects limit the aesthetic quality and design flexibility
Solution Approach 1:
The embossing system becomes dynamic through temperature control, allowing the same production line to produce different embossed patterns by simply adjusting the temperature of the embossing material. This enables design flexibility without compromising production efficiency, as no physical reconfiguration of the production line is needed.
Solution Approach 2:
The temperature-responsive embossing material serves multiple functions: it provides consistent embossing when cured at controlled temperatures, enables pattern variation when melted and reformed, and can be reused indefinitely. This single material system replaces multiple specialized steel plates, achieving multi-functionality while maintaining production efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the production of advanced decorative patterns with variable embossing in register with digital décor, enabling larger floor areas with distinct panel designs, reducing production costs and complexity, and eliminating the need for expensive embossed steel plates or rollers.
Implementation Method 1
The curable ink may be a polymer material, preferably a UV curing polymer material
Data Source
Figure 1a~1d
Figure 2a~2e
Figure 3a~3f
AI summary
The disclosure relates to a method of forming an embossed surface on a building panel. The method comprises the step of providing a substrate, forming an ink matrix (41) by applying a curable ink (25) on an upper part of the substrate by means of a digital ink head, and forming a cavity in a surface layer (2) of the building panel by pressing a lower part of the substrate and the ink matrix located on the upper part of the substrate against the surface layer of the building panel, thereby forming an embossed surface of the building panel. Finally, the method comprises the step of removing the substrate with the ink matrix from the embossed surface.