Digital Lacquer Spraying for Decorative Surface Gloss Control
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Solution Overview
Problem
Existing methods for producing decorative surfaces, such as those mimicking wood or stone, are inefficient in creating visually and haptically appealing designs due to the complexity and time-consuming process of producing embossing tools, and the high cost associated with changing these tools for different designs.
Innovation Solution
A method involving digital printing stations where a first lacquer layer is applied to a workpiece, followed by a second lacquer layer with varying gloss levels, achieved through digitally spraying droplets of lacquer, allowing for quick adjustment of gloss levels without the need for tool changes, and incorporating structured base layers for enhanced tactile effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If embossing tools are used to create tactile structure, then surface texture quality is improved, but device complexity and production time increase
Solution Approach 1:
The patent uses digital printing to create optical copies of wood grain patterns and applies lacquer that mimics the appearance of embossed surfaces. Instead of physically embossing the substrate, the invention digitally reproduces the visual and tactile appearance of wood grain through printed patterns and gloss variations, eliminating the need for complex physical embossing tools while achieving similar aesthetic effects
Solution Approach 2:
The invention replaces the mechanical embossing system with a digital printing and lacquer application system. Instead of using physical dies and pressing mechanisms to create surface structure, the patent uses digital printers to apply patterns and lacquer with varying gloss levels, substituting mechanical structure creation with digital pattern deposition and optical property modification
2Adaptability or versatility
If embossing tools are changed for different designs, then product variety is improved, but production time increases
Solution Approach 1:
The patent implements a dynamic, reconfigurable printing system that can be rapidly reprogrammed for different designs. The digital printing station can change patterns, colors, and gloss distributions by simply updating digital files, allowing quick adaptation to different wood grain types and decorative styles without physical tool changes, enabling flexible production of varied decorative surfaces
Solution Approach 2:
The digital printing and lacquer application system serves multiple functions: it can print various wood grain patterns, create different gloss levels, and produce diverse decorative effects all through a single integrated station. This universal system replaces multiple specialized embossing tools, allowing one device to perform the work of many different physical tools through digital reconfiguration
3Manufacturing precision
If multiple lacquer layers with different gloss levels are applied, then visual realism is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies lacquer with spatially varying gloss levels to different regions of the surface. By controlling the lacquer application to create high-gloss areas in wood pore regions and lower-gloss areas in surrounding regions, the invention locally differentiates surface properties to enhance the realism of wood grain reproduction, with each region having optimized optical characteristics for its specific function
Solution Approach 2:
The invention changes the gloss parameter of the lacquer layer across different areas of the surface. By varying the gloss level from high to low in different regions, and by controlling droplet size and distribution, the system creates realistic wood grain appearance through parameter variation rather than through complex multi-step coating processes, simplifying the manufacturing while achieving visual realism
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 enables rapid and cost-effective production of decorative surfaces with varying gloss levels and textures, allowing for quick changes between designs without the need for specialized embossing tools, resulting in visually and haptically appealing finishes.
Implementation Method 1
droplets of at least partially transparent lacquer are digitally sprayed onto portions of the first lacquer layer on the workpiece to apply a second lacquer layer
Implementation Method 2
The applied coating layers are finally dried physically and/or chemically cured
Implementation Method 3
The applied coating layers are finally dried physically and/or chemically cured
Data Source
Figure 1~2
Figure 3
AI summary
A method for producing a decorative surface with different gloss levels preferably comprises the following steps: (A) feeding a workpiece (1.0) to a coating application device; (B) coating the workpiece (1.0) with at least one first coating layer (1.4); (C) feeding the workpiece to a digital printing station; (D) providing digital control data for the digital printing station; (E) digitally spraying droplets of at least partially transparent lacquer onto partial areas of the first coating layer (1.4) on the workpiece (1.0) to apply a second coating layer (1.5) to the first coating layer (1.4), wherein the second coating layer (1.5) has a different gloss level than the first coating layer (1.4) after curing; and (F) physical drying and/or chemical curing of the applied coating layers (1.4, 1.5). Furthermore, a device for carrying out the method is provided.