Digitally printed plate, manufacturing method, and application

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current decorative panel manufacturing processes are inefficient and costly due to the need for time-consuming and expensive pattern rolls, which fail to meet personalized customization requirements and result in high production costs and long lead times.

Innovation Solution

A digital printed plate structure comprising a surface lacquer layer, texture layer, wear layers, pattern layer, bottom lacquer layer, and base layer, utilizing UV coatings and multiple color UV oil ink printing to enable customizable, stereoscopic textures without the need for pre-made pattern rolls, with adjustable chemical polarity for improved adhesion and protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional pattern rolls are used for decorative panel manufacturing, then consistent patterns can be achieved, but manufacturing time and cost increase significantly

Engineering Contradiction:

Improvepattern consistencyVSAvoidmanufacturing lead time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent uses digital printing technology to create high-resolution digital images that replicate natural wood grain patterns and other textures directly on the decorative panel surface. This digital copying approach eliminates the need for physical pattern rolls while maintaining pattern consistency through precise digital reproduction and UV curing processes

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The invention replaces the mechanical pattern roll system with a digital printing system that uses UV inkjet printers to deposit and cure pattern-forming materials directly onto the panel. This substitution of mechanical rolling with digital printing and photopolymerization dramatically reduces manufacturing time while preserving pattern consistency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If traditional hot pressing with emboss board is used to create surface embosses, then wear resistance is improved, but manufacturing cost and time increase

Engineering Contradiction:

Improvewear resistanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the physical state and curing parameters of the coating material by using UV photopolymerization instead of thermal hot pressing. The UV-curable adhesive lacquer and wear-resistant lacquer are applied in liquid form and then rapidly cured by UV light, creating hard, wear-resistant surfaces without the need for high-temperature pressing equipment

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention utilizes the phase transition of UV-curable materials from liquid to solid through photopolymerization. The adhesive lacquer and wear-resistant lacquer are applied as liquid coatings that contain photopolymerizable monomers and oligomers, which undergo rapid polymerization when exposed to UV light, transforming from fluid to solid state and creating durable, wear-resistant surfaces

Inventive Principle:

Principle #36Phase transitions

3Productivity

If pattern rolls are made in advance for customization, then production efficiency is maintained, but customization flexibility is reduced

Engineering Contradiction:

Improveproduction efficiencyVSAvoidcustomization capability

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent implements a dynamic, flexible manufacturing system where the digital printing parameters (ink composition, printing patterns, UV curing conditions) can be rapidly adjusted between production runs. This allows the same equipment to efficiently produce different customized patterns without requiring pre-made pattern rolls, combining high productivity with full customization capability

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The digital printing system serves multiple functions: it can print various patterns, create different textures, apply adhesive layers, and provide wear resistance all in one integrated process. This multi-functional approach eliminates the need for separate pattern rolls for different designs while maintaining production efficiency

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution allows for efficient, cost-effective production of customizable decorative panels with varied patterns and textures, reducing manufacturing time and costs, enabling personalized designs and easy application in different environments.

Implementation Method 1

roll coating transparent UV surface lacquer on texture layer and light curing

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS20240125128A1Digitally printed plate, manufacturing method, and application

Publication Date: 2024.04.18 TAIZHOU HUALI PLASTIC

AI summary

This invention discloses digitally printed plate, the manufacturing method and applications thereof, is characterized in that the digitally printed plate is of respectively from top to bottom surface lacquer layer, texture layer, second wear layer, first wear layer, pattern layer, bottom lacquer layer, base layer. The digitally printed plated has various patterns, with sufficient materials, printing unrepeatable stereoscopic pattern is possible, so it can satisfy customers' personalized customization requirements, without wasting abundant time or cost, and with process reduced, production efficiency is improved, enabling order manufacturing order insert and sample making at any time.