Digital Relief Printing for Deeper, Sharper Panel Recesses
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing digital printing techniques for reliefs on substrates produce narrow, shallow, and less defined recesses, or suffer from limited mechanical resistance and high production costs, failing to achieve desired depth and surface finish quality.
Innovation Solution
A method involving digital printing with two distinct volumes of liquid recess printing product droplets on a substrate, where a first volume forms recess areas and a second, lower volume forms adjacent no-recess areas, enhancing definition and smoothness by confining droplets and facilitating removal of the mixed material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If digital printing with liquid recess printing product is used to produce reliefs, then definition and precision are improved, but recess depth and volume are limited
Solution Approach 1:
The patent applies preliminary action by first extending a liquid relief base layer onto the substrate before digitally printing the recess printing product. This preliminary preparation creates a receptive medium that allows subsequent droplet deposition to form deeper and more voluminous recesses, as the liquid base layer can be removed after curing to reveal the three-dimensional relief structure.
Solution Approach 2:
The patent utilizes parameter changes by controlling droplet volume, deposition density, and curing parameters to transform the flat liquid relief base layer into a three-dimensional relief structure. By varying these parameters during the printing and curing process, the system achieves both high definition precision and increased recess depth simultaneously.
2Volume of moving object
If higher volume per area of recess printing product is used, then recess depth increases, but definition and sharpness decrease
Solution Approach 1:
The patent applies local quality by digitally controlling the deposition parameters of the recess printing product at different locations on the relief base layer. The system can vary droplet volume, spacing, and density locally to achieve optimal recess depth in specific areas while maintaining sharp boundaries and high definition in adjacent areas, thus resolving the contradiction between depth and precision.
3Productivity
If conventional embossing or moulding is used, then production speed is maintained, but definition and precision are reduced
Solution Approach 1:
The patent replaces conventional mechanical embossing or moulding systems with a digital printing system that deposits liquid recess printing product onto a liquid relief base layer. This substitution eliminates the need for physical contact between printing heads and the substrate, enabling high-speed digital fabrication while achieving superior definition and precision through non-contact droplet deposition and selective curing.
4Volume of moving object
If digital embossing technique is used, then recess depth can be controlled, but mechanical resistance and surface finish quality are limited
Solution Approach 1:
The patent employs composite materials by combining the relief base layer material with the recess printing product material. This composite structure, formed by the interaction between the base layer and deposited droplets, enhances both the mechanical resistance and surface finish quality of the final relief while maintaining controlled recess depth, as the composite provides structural integrity and improved surface properties.
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 method produces reliefs with improved definition, precision, and surface finish, allowing for recesses of varying widths and depths with reduced roughness and improved mechanical resistance, resulting in high-quality textures.
Implementation Method 1
The use of substances with an appropriate surface energy or tension is known, as well as the use of repellent or immiscible agents between the printing product and the relief base layer, which make it possible to reduce or override the wettability of the printing product in the relief base layer.
Implementation Method 2
the use of substances with an appropriate surface energy or tension is known, as well as the use of repellent or immiscible agents between the printing product and the relief base layer, which make it possible to reduce or override the wettability of the printing product in the relief base layer.
Implementation Method 3
using a relief base layer of UV-curable resin. Once the relief base layer is extended on the substrate, the liquid printing product is digitally printed on the liquid relief base layer, which has not been cured or is partially cured. The relief base layer is cured together with the mixed printing product.
Data Source
Figure 1
Figure 2
Figure 3a~4
AI summary
A method for producing a relief (20) on a substrate (3), the relief (20) comprising a recess area (21) and a no-recess area (22), the recess area (21) being adjacent to the no-recess area (22) and forming a recess with respect to the no-recess area (22). The method comprises extending a relief base layer (2) on the substrate (3), digitally printing with a first volume per area (41) of printed product on the outer surface of the extended relief base layer (2) to obtain the recess area (21), the recess area (21) forming the recess with respect to the outer surface of the extended relief base layer (2), and digitally printing with a second volume per area (42) of printed product on the outer surface of the extended relief base layer (2) at least adjacently to the recess area (21), to obtain the no-recess area (22).