Surface Materials with Embedded Images via UV Curing
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Solution Overview
Problem
Existing surface material manufacturing processes are labor-intensive and result in unsatisfactory appearances, with gel-coated materials often appearing cloudy and images becoming blurry, and exposed surfaces experiencing inconsistent wear and fading, especially in outdoor applications like vehicle panels.
Innovation Solution
The process involves printing textures and images directly onto a raw substrate surface without a gel coat, using digital printing and UV curing to diffuse the layers into the substrate, followed by a resinous topcoat for enhanced adhesion and protection, allowing for larger sizes and precise, high-resolution images with improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gel coat is applied to the mold before backfilling substrate material, then the mold is protected and provides a smooth surface, but the finished material appears cloudy and images become blurry
Solution Approach 1:
The patent removes the gel coat layer from the manufacturing process entirely. Instead of applying a protective gel coat to the mold, the invention uses a release agent applied directly to the mold surface, eliminating the intermediate layer that causes cloudiness and blurriness in the finished product.
Solution Approach 2:
The patent introduces a release agent as an intermediary substance between the mold and substrate material. This release agent provides the necessary mold protection and release functionality without creating the optical defects associated with gel coats, maintaining both reliability and image clarity.
2Adaptability or versatility
If images are applied to the inner surface of gel coat through painting or transfer films, then images can be incorporated into the material, but the process requires significant labor and multiple intermediate steps
Solution Approach 1:
The patent combines the image application and substrate backfilling steps into a single integrated process. Images are applied directly to the mold surface (replacing the gel coat), and then substrate material is backfilled over them, eliminating the need for separate gel coat application, curing, and image application steps.
Solution Approach 2:
The patent performs image application as a preliminary action directly on the mold surface before substrate backfilling. This approach allows images to be incorporated into the material structure itself during the forming process, rather than requiring post-forming application methods that add labor and time.
3Adaptability or versatility
If adhesive decals are used to apply images to the substrate, then images can be added to the surface material, but additional surface processing steps are required and wear consistency is compromised
Solution Approach 1:
The patent removes the adhesive decal layer and associated application mechanisms from the process. Instead of applying separate adhesive decals to the cured substrate, images are applied directly to the mold and become integrated into the material structure during forming, eliminating the need for additional surface processing steps.
4Manufacturing precision
If mixed colored resins are used to create appearance effects during backfilling, then natural appearances can be achieved, but the process requires manual mixing and precise control
Solution Approach 1:
The patent segments the appearance creation process into two distinct parts: (1) images applied directly to the mold surface providing the base appearance, and (2) uniformly colored substrate material backfilled over the images. This eliminates the need for complex manual mixing of colored resins while maintaining appearance quality through the integrated image-substrate structure.
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 method reduces manufacturing costs and labor, enhances appearance and durability, and ensures consistent wear resistance and color fidelity, particularly in outdoor applications by eliminating intermediate layers and manual processes.
Implementation Method 1
The resinous composition is applied over the printed textures and images and cured to complete the process
Data Source
AI summary
The disclosure relates to methods of manufacturing surface materials for construction or manufacturing use and the surface materials produced by such methods. Substrate materials, such as synthetic or engineered stone or fiber-reinforced resinous panels, can be formed in conventional ways such as casting, molding, or pressing. Layers are printed onto substrate materials to form textures, which may include inks to selectively color the printed texture, thereby enabling a wide variety of high-resolution appearances. A clear, protective topcoat is then applied to the surface materials and cured to provide a finished material.