Digital Pattern Scaling for Embossed Surface Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing processes for producing surface coverings with embossed printed surfaces face challenges in preventing or reducing misalignments between the printed and embossed patterns, often requiring substrate stretching that leads to transverse deformation and necessitating extensive equipment.
Innovation Solution
A process where the printed pattern is dynamically stretched or compressed in-line with the embossed pattern using digital printing equipment, allowing for real-time correction of misalignments without substrate stretching, using angular encoders and velocity control to maintain alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the substrate is stretched to adjust the pitch of the printed pattern, then the alignment between printed and embossed patterns is improved, but transverse necking and deformation of the substrate occur
Solution Approach 1:
The patent uses a digital copy of the printed pattern that can be independently scaled and transformed. By creating a digital model of the pattern and applying mathematical transformations (scaling factors in x and y directions, rotation angles) to this digital copy, the system can correct misalignments without physically deforming the substrate. The transformed digital pattern is then used to control the printing positions, achieving alignment correction through information processing rather than mechanical stretching.
Solution Approach 2:
The patent replaces the mechanical stretching system with a digital processing system. Instead of using mechanical devices to physically stretch the substrate and printed pattern, the invention uses digital image processing, coordinate transformation algorithms, and computer-controlled printing positioning. This substitution eliminates the need for mechanical deformation while achieving the same alignment correction goal through computational methods.
2Manufacturing precision
If multiple heated cylinders are used to stretch the substrate, then the printed pattern alignment is improved, but the device complexity increases considerably
Solution Approach 1:
The patent creates a digital copy of the desired pattern and uses coordinate transformation algorithms to calculate the correct printing positions. This digital model can be scaled and transformed mathematically to compensate for any misalignment, eliminating the need for complex mechanical stretching equipment. The transformation parameters (scaling factors, rotation angles) are computed based on measured misalignment and applied to the digital printing data.
Solution Approach 2:
The patent replaces the entire mechanical stretching system with a digital processing system. Instead of using heated cylinders and mechanical stretching devices, the invention uses computer-controlled digital image processing and precision printing positioning. The alignment correction is achieved through software algorithms that transform the digital pattern coordinates, eliminating the need for complex mechanical equipment while maintaining or improving alignment precision.
3Manufacturing precision
If the substrate is stretched to correct misalignment, then the printed pattern registration is improved, but the process requires the substrate to be easily stretchable which limits substrate choice
Solution Approach 1:
The patent replaces mechanical stretching with digital processing, allowing the use of any substrate material regardless of its stretchability. The digital coordinate transformation system can correct misalignments for any substrate type by adjusting the digital printing positions, eliminating the requirement for substrates to be easily stretchable. This enables the process to handle rigid, flexible, thick, or thin substrates without modification.
Solution Approach 2:
The patent changes the approach from physically altering the substrate to digitally altering the printing parameters. By modifying the digital printing data (coordinates, scaling factors, rotation angles) rather than the physical substrate properties, the system can achieve alignment correction for any substrate material. This parameter change in the control system enables universal applicability across different substrate types.
4Manufacturing precision
If the printed pattern is stretched in longitudinal direction, then the pitch alignment is improved, but transverse deformation occurs making simultaneous alignment in both directions difficult
Solution Approach 1:
The patent uses a digital copy of the pattern that can be independently scaled in both x and y directions without causing coupled deformation. The digital transformation allows separate adjustment of longitudinal and transverse dimensions, enabling independent optimization of alignment in both directions. This decoupled digital scaling eliminates the transverse necking effect that occurs with mechanical stretching.
Solution Approach 2:
The patent implements a dynamic digital transformation system that can independently adjust scaling factors and rotation angles for different directions. The coordinate transformation algorithm allows separate control of longitudinal and transverse dimensions, enabling the system to adaptively correct misalignments in both directions simultaneously without the coupled deformation effects of mechanical stretching.
Data Source
Figure 1~2
Figure 3A~3C
AI summary
A process for producing a surface covering with an embossed printed surface is proposed. A substrate (16) is continuously moved through a production line, and this substrate (16) is first provided, in a printing equipment (12), with a printed pattern and thereafter, in an embossing equipment (14),with an embossed pattern, which is registered with the printed pattern. The printing equipment (12) produces the printed pattern in-line with the production of the embossed pattern. During printing in the printing equipment (12), the printed pattern is stretched or compressed, dynamically responsive to indicators of misalignments between the printed pattern and the embossed pattern, so as to correct or prevent the misalignments.A production line for carrying out this process is also proposed.