Digital flocking process
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Solution Overview
Problem
Current flocking processes result in inaccurate and uniform flocking characteristics across the surface, limiting their suitability for mass production and failing to achieve variable flocking intensities or patterns, which are typically achieved through analog and manual methods.
Innovation Solution
A digital flocking process using intensity-tunable adhesive application, where the adhesive composition is digitally printed at varying resolutions and densities, allowing for precise control over flock deposition, enabling images with variable flocking intensities and patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If analog adhesive application methods (roller, brush, spray) are used, then the process is simple to operate, but the manufacturing precision and accuracy of the flocking pattern are poor
Solution Approach 1:
The patent replaces mechanical adhesive application methods (roller, brush, spray) with a digital inkjet printing system that deposits adhesive in a digitally controlled manner. This substitution enables precise control over adhesive placement, density, and intensity at different locations, directly improving flocking pattern accuracy while maintaining operational simplicity through digital design files.
Solution Approach 2:
The patent implements variable adhesive parameters (density, intensity, droplet size) that can be independently controlled at different locations on the substrate. By changing these parameters digitally, the system achieves high manufacturing precision for flocking patterns without requiring complex mechanical adjustment mechanisms, thus resolving the contradiction between precision and device complexity.
2Adaptability or versatility
If uniform adhesive layer is applied, then the application process is simple, but the flocking characteristics (density, color, appearance) are uniform and lack variability
Solution Approach 1:
The patent applies adhesive with locally varied properties (different densities, intensities, and droplet sizes) at different locations on the substrate. This local quality approach enables diverse flocking characteristics (density, color, appearance) across different regions while maintaining precise control over each local area's adhesive properties, thus achieving both adaptability and manufacturing precision.
Solution Approach 2:
The patent implements a dynamic adhesive application system where parameters such as adhesive density, intensity, and droplet size can be continuously varied during the printing process. This dynamic control allows the system to adapt to different design requirements and achieve variable flocking characteristics without compromising the precision of adhesive placement.
3Productivity
If manual multi-stage operations are used, then the process can achieve complex patterns, but the productivity and mass production capability are limited
Solution Approach 1:
The patent merges multiple manual operations (adhesive application, pattern creation, flocking) into a single integrated digital inkjet printing process. The inkjet system simultaneously performs adhesive deposition, pattern definition, and intensity modulation in one pass, dramatically improving productivity and enabling mass production while simplifying the operational process through digital file-driven control.
Solution Approach 2:
The patent uses digital design files as templates that can be repeatedly copied and applied to multiple substrates with consistent precision. This copying approach enables mass production of identical or varied flocking patterns without requiring manual reconfiguration, thus improving productivity while maintaining ease of operation through digital replication.
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
The process achieves high-resolution, multi-tonal flocking images with controlled flocking intensities and densities, enhancing the accuracy and versatility of flocking applications, suitable for mass production.
Implementation Method 1
digitally printing a first adhesive composition directly on a surface of a substrate at a range of DPI values
Implementation Method 2
flocking the surface using a first flock material
Data Source
AI summary
The instant disclosure provides a process for forming an image in flock, which involves digitally printing an adhesive composition directly on a substrate surface, preferably by modifying the amount of the adhesive based on a linearization curve, flocking the surface with a flock material, and curing the image. The instant disclosure also provides a method for obtaining a linearization curve for digital flocking, which involves forming a pattern using an adhesive composition, flocking the pattern with a flock material, curing the flocked image to obtain a flocked greyscale image, and measuring the flock intensity to obtain the linearization curve, whereas the linearization curve is unique for a set of given conditions and can be implemented in RIP commands to modify DPI values for digital flocking. An image comprising regions with more than one flock intensity is also described.