Digital Printing Floorboard Embossing for Stereoscopic Patterns
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current digital printing technologies for floorboards struggle to achieve an integral three-dimensional visual effect, as flat patterns do not accurately correspond to stereoscopic patterns, making them aesthetically unappealing and inefficient to produce.
Innovation Solution
A digital printing method involving a base material layer, a printing layer directly printed by a digital apparatus, and a protection layer applied through various processes like roll-coating, spray-coating, and embossing, which creates artistic effects such as sunken, raised, and patterned designs, ensuring correspondence and aesthetic appeal of stereoscopic patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flat patterns are printed on the printing layer, then the production process is simple, but the three-dimensional visual effect cannot be achieved and the aesthetic appeal is poor
Solution Approach 1:
The patent applies dimensionality change by transitioning from flat two-dimensional printing to three-dimensional stereoscopic patterns. The printing layer is processed through embossing, corroding, or carving techniques that add vertical depth, transforming flat printed patterns into raised or sunken three-dimensional patterns that create realistic wood grain effects and enhance aesthetic appeal while maintaining the underlying simple printing process.
Solution Approach 2:
The patent changes the physical parameters of the printing layer by applying thermal or mechanical processing after printing. Through embossing (thermal pressing), corroding (chemical etching), or carving (mechanical removal), the printing layer's surface topology is modified to create three-dimensional patterns. This parameter change transforms the flat printed pattern into a stereoscopic structure that accurately corresponds to the printed design.
2Productivity
If traditional printing methods are used, then the production efficiency is limited, but achieving accurate correspondence between flat and stereoscopic patterns is difficult
Solution Approach 1:
The patent replaces traditional mechanical printing and pattern transfer methods with digital printing technology. The digital printing apparatus directly prints patterns onto the printing layer with high precision, eliminating the need for complex mechanical pattern transfer processes. This substitution enables both high production efficiency through rapid digital printing and accurate correspondence between the printed patterns and the subsequent three-dimensional patterns created through embossing or corroding.
Solution Approach 2:
The patent discards the intermediate step of creating physical pattern masters or films required in traditional methods. By using digital printing, the pattern information is directly transferred from digital data to the printing layer, eliminating the need for physical pattern carriers. This recovery of the direct digital-to-product pathway significantly improves both production efficiency and pattern accuracy.
3Shape
If multiple processing steps are added to create stereoscopic patterns, then the aesthetic appeal improves, but the production complexity increases
Solution Approach 1:
The patent merges the printing and three-dimensional pattern creation processes into an integrated workflow. The digital printing step is followed by a single unified processing step (embossing, corroding, or carving) that simultaneously creates the three-dimensional effect. This merging eliminates the need for separate pattern transfer, alignment, and processing steps required in traditional methods, reducing overall process complexity while maintaining high stereoscopic pattern quality.
Solution Approach 2:
The patent employs a universal processing approach where a single type of processing (embossing, corroding, or carving) can be applied to create various three-dimensional patterns from different digital prints. The same basic equipment and process methodology can produce different stereoscopic effects by varying the digital pattern design and processing parameters, reducing the need for multiple specialized processes and equipment.
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 enhances the aesthetic appeal of stereoscopic patterns, improves production efficiency, and ensures stable product quality by allowing for customizable and accurate three-dimensional designs.
Implementation Method 1
curing with a UV lamp
Data Source
AI summary
A method for processing floorboards using digital printing, comprising: preparing a base material layer; arranging a printing layer on the base material layer, wherein the printing layer is directly printed by a digital printing apparatus and is formed on a surface of the base material layer; and arranging a protection layer on the printing layer, wherein the protection layer is attached to the printing layer by means of one or a combination of processes selected from roll-coating, shower-coating, spray-coating, transfer-printing and printing, wherein the protection layer displays one or a combination of artistic effects selected from flat, sunken, raised, finely creased, patterned and crackled by means of one or a combination of processes selected from levelling, flatting, printing, embossing, corroding, carving, brushing and crackling. According to the processing technology of the present disclosure, various patterns can be designed and processed in different ways or combinations according to the user's requirements.