Embossed Coating Structure for Mask-Free Matte Surface Variation

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Solution Overview

Problem

Existing coating structures for substrates require masking to achieve design variations in coating material layers, which is inefficient and costly, and often result in high glossiness that may not meet aesthetic or functional requirements.

Innovation Solution

A coating structure with a substrate having base surface indentations and projections of varying depths and spacings, where a single coating material forms a layer with corresponding indentations and projections, allowing for design differences without masking and reducing glossiness through controlled embossing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If masking is used to achieve design variations in coating material layers, then design flexibility is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvedesign flexibilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The substrate surface is pre-formed with indentations and projections of varying depths in different areas before coating is applied. This preliminary structuring of the substrate allows the single-layer coating to inherit and reflect these variations, creating design effects without requiring masking during the coating process itself.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Different areas of the substrate surface are given different local characteristics through varying the depth of indentations and projections in specific regions. This local variation in surface topology creates area-specific optical properties that produce design variations in the final coated appearance without requiring different materials or masking.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If masking is used to create design variations, then design flexibility is improved, but production time and cost increase

Engineering Contradiction:

Improvedesign flexibilityVSAvoidproduction efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The substrate surface structure is pre-formed with the desired indentation and projection patterns before the coating process. This allows the design variations to be built into the substrate itself, eliminating the need for time-consuming masking operations during coating and thereby improving production efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The design variation function is extracted from the coating process itself and transferred to the substrate preparation stage. By creating the surface topology variations in the substrate before coating, the complex masking operations are eliminated from the coating process, streamlining production.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If a single coating material is used, then manufacturing simplicity is improved, but design flexibility deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoiddesign flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

Different areas of the single coating layer are given different local appearances through the varying depths of substrate indentations and projections. The uniform coating material reflects light differently across areas with different surface topologies, creating design variations while maintaining manufacturing simplicity of using a single material.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The optical appearance of the coating is varied by changing the physical parameters of the substrate surface (indentation depth, projection height) rather than changing the coating material itself. This allows design flexibility to be achieved through geometric parameter variation while maintaining the simplicity of applying a single coating material.

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If conventional coating methods are used, then manufacturing simplicity is maintained, but glossiness control deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidsurface finish

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

Different areas of the substrate surface are structured with different indentation and projection characteristics to create local variations in light reflection. Areas with deeper indentations produce matte appearances while areas with shallower features maintain higher gloss, allowing controlled surface finish variation across the coated surface.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The substrate surface is pre-structured with the desired indentation and projection patterns before coating is applied. This preliminary surface preparation enables control over the final surface finish and glossiness characteristics without requiring complex post-coating processing or specialized coating materials.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20240359209A1Coating structure

Publication Date: 2024.10.31 KK TOKAI RIKA DENKI SEISAKUSHO

AI summary

A coating structure is provided with embossed portions on a base surface of a substrate, with a coating material layer covering the base surface. A depth of the embossed portions in a one-side area is larger than a depth of the embossed portions in an intermediate area, and on a surface of the coating material layer, a depth of one-side indentations and projections in the one-side area is larger than a depth of intermediate indentations and projections in the intermediate area.