Digital Inkjet Lacquer Deposition for High-Resolution 3D Surface Structures
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Solution Overview
Problem
Current methods for creating three-dimensional surface structures on workpieces, such as laminate flooring and furniture, face limitations in structure fineness, adaptability to underlying decorative images, and efficiency in changing patterns, particularly with radiation-curing acrylate systems, which restrict the production of detailed and synchronized haptic impressions.
Innovation Solution
A method involving the application of a transparent or monochromatic radiation-curing lacquer using inkjet print heads, allowing for quick changes and producing defined matte and glossy areas, with a surface structure that matches the underlying decorative image, including synchronized pores and textures, using multiple print heads and controlled droplet sizes and curing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rubberized applicator roller with grooves or laser-structured surface is used to apply structure, then a three-dimensional surface structure can be created, but the fineness of the structure is restricted and cannot achieve high-resolution detailed patterns
Solution Approach 1:
The patent replaces the mechanical rubberized applicator roller system with a digital printing system that uses inkjet print heads to deposit lacquer droplets. This substitution enables high-resolution structure creation through digital control of droplet placement rather than mechanical contact, achieving structure fineness beyond the capabilities of traditional mechanical rollers while reducing the technical effort of pattern changes through software control
Solution Approach 2:
The patent changes the fundamental parameter of structure application from mechanical contact (roller grooves) to controlled droplet deposition (inkjet printing). By controlling droplet size, placement position, and curing parameters, the system achieves high-resolution structures without the physical constraints of mechanical contact, allowing flexible pattern changes without hardware reconfiguration
2Adaptability or versatility
If a structured press plate with elevations and depressions is used during curing, then a structured surface corresponding to wood grain can be created, but the adaptability to different decorative images is limited
Solution Approach 1:
The patent implements a dynamic system where the structure pattern is determined by software control of the inkjet print heads rather than a fixed physical press plate. This allows the structure to be dynamically adapted to match any decorative image pattern, including complex designs like tile joints, while maintaining precise synchronization through digital positioning control
Solution Approach 2:
The digital printing system serves multiple functions: it can create various structure types (wood grain, tile joints, geometric patterns), adapt to different decorative images, and modify patterns in real-time without changing physical hardware. This universal capability replaces the need for multiple specialized press plates and enables single-machine versatility across different application types
3Productivity
If a rubberized applicator roller is used to apply structure, then a three-dimensional surface can be created, but the quick change capability between different structure patterns is restricted
Solution Approach 1:
The patent replaces the mechanical roller system requiring physical reconfiguration with a digitally controlled inkjet system. Structure patterns are changed through software programming rather than mechanical adjustment, enabling instant pattern changes between different decorative designs without the complexity of reconfiguring physical rollers or press plates
Solution Approach 2:
The system uses preliminary digital programming to store different structure patterns and decorative image configurations. Before production, the desired patterns are pre-loaded into the digital control system, allowing immediate recall and application of stored patterns without physical reconfiguration during production, significantly improving change efficiency
4Manufacturing precision
If transparent radiation-curing acrylate lacquer is applied as top layer, then scratch resistance and haptic impression are provided, but the control over different gloss levels in different areas is restricted
Solution Approach 1:
The patent applies local quality by using the inkjet printing system to deposit lacquer droplets with controlled properties in specific locations. Different droplet characteristics (gloss level, structure type) can be applied to different areas of the workpiece simultaneously or sequentially, enabling multi-zone gloss control without requiring complex multi-component systems or sequential processing steps
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
Enables the creation of high-resolution, adaptable, and visually appealing three-dimensional surface structures that closely match the underlying decorative image with reduced technical effort, achieving precise control over structure height and gloss levels, and allowing for efficient production of complex designs.
Implementation Method 1
a UV-curing digital printing ink is very often used according to the prior art, which contains an acrylate as the main basis, which is mixed with special photoinitiators and thus cures under irradiation, e.g. with UV rays or electron beams
Data Source
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AI summary
The invention relates to a method and device for generating a three dimensional surface structure on a work piece comprising the following steps: feeding a work piece printed with a décor pattern to a processing station; spraying a transparent, radiation-curing varnish through a plurality of nozzle openings onto the surface of the work piece in the form of varnish droplets, wherein the individual varnish droplets have a volume of 0.5 - 300 pl, preferably 3 - 80 pl, particularly preferably 10 - 50 pl, and the number of varnish droplets per surface unit and/or the volume of varnish droplets occurs by means of computer control according to a digital template; and curing of the transparent varnish by means of radiation, preferably by means of UV radiation.