Flat Substrate 3D Relief Printing With Immiscible Coating Layers
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Solution Overview
Problem
Current methods for producing 3D structures on substrates are inflexible, lack precision, and are complex in calculating droplet interactions, especially at high printing speeds, making it difficult to accurately reproduce natural materials like wood or stone.
Innovation Solution
A method involving the application of a relief product in droplet form, followed by a covering product that reacts immiscibly with the relief product, allowing precise control over the 3D structure formation through differential surface tensions and controlled drying, with optional removal of the relief product to define the final structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If droplets of a second product are projected onto a layer of a first product to create 3D structures, then flexibility in relief reproduction is improved, but manufacturing precision deteriorates due to droplet interaction complexity and positioning inaccuracies
Solution Approach 1:
The patent applies a masking layer before projecting droplets, preparing the surface in advance to control droplet placement. The masking layer is selectively removed after droplet application, ensuring precise relief formation without complex calculations of droplet interactions.
Solution Approach 2:
The masking layer acts as an intermediary between the droplets and the final substrate surface. It controls where droplets are deposited and how they interact with the substrate, simplifying the precision requirements by mediating the droplet-substrate interaction.
2Manufacturing precision
If multiple product properties and layer thickness parameters are considered to calculate droplet positioning, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the complexity of droplet interaction calculations by using a masking layer approach. Instead of calculating droplet behavior, the system uses physical masks to define droplet placement, removing the need for complex computational models.
Solution Approach 2:
The masking layer is a temporary, disposable element used only during the droplet application process. It simplifies the system by being a simple removable component rather than a complex calculation system, achieving precision through physical rather than computational means.
3Productivity
If high printing speeds are used to increase productivity, then productivity is improved, but manufacturing precision deteriorates due to increased droplet displacement and interaction complexity
Solution Approach 1:
The masking layer is applied before high-speed droplet projection, preparing the surface in advance. This allows droplets to be deposited at high speeds onto a pre-positioned mask without requiring complex real-time calculations to compensate for droplet displacement.
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 enhances precision and flexibility in creating 3D structures, simplifies calculations, and improves the quality of the relief reproduction by ensuring accurate depth and texture definition on the substrate surface.
Implementation Method 1
The relief product and the covering product comprise properties, including different respective surface tensions
Implementation Method 2
the relief product and the covering product comprise properties, including different respective surface tensions, such that they are immiscible with each other
Implementation Method 3
fixing the layer of the covering product to obtain the selected positions on the face free from the covering product
Data Source
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AI summary
The invention relates to a method for producing a three-dimensional structure on a face (1') of a flat substrate (1), a device for implementing the method, and the substrate (1) that can be produced, said method comprising the following steps: providing the substrate (1) with the face (1') ready to be treated; applying a relief product (2) in the form of droplets on the face (1'), such that selected positions of droplets are produced on the face (1'); applying a covering product (3) to the face (1') such that it forms a layer over the face (1'); and fixing the layer of the covering product (3) obtaining the selected positions on the face (1') free from the covering product (3).