Foamed Structure Printing via Preliminary Action on Expanding Layer
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Solution Overview
Problem
Existing methods for forming foamed structures struggle to achieve high-quality printing on expanded surfaces, particularly when using offset printing systems, as they are designed for flat surfaces, leading to inefficiencies and reduced printing quality.
Innovation Solution
A method involving the formation of a photo-thermal conversion material on a medium with an expanding layer before expansion, followed by the application of white and coloring materials, which are then expanded using heat, allowing for high-quality printing with offset printing systems, even when using ink-jet or laser printers designed for flat surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If printing is performed on the medium after the surface has been expanded, then the structure can be formed, but the printing quality deteriorates and printing speed decreases
Solution Approach 1:
The patent applies preliminary action by performing all printing operations on the medium before the expanding layer is heated and expanded. The base layer, expanding layer, and any additional layers are printed and prepared in sequence while the medium remains flat, ensuring high printing quality with standard printers. Only after printing is complete is the expanding layer heated to create the three-dimensional structure, thus avoiding the problem of printing on irregular surfaces.
2Adaptability or versatility
If a standard ink-jet or laser printer is used on expanded surfaces, then device versatility is maintained, but printing quality deteriorates
Solution Approach 1:
The invention resolves this contradiction by performing all printing operations before the expanding layer is activated. Standard ink-jet or laser printers can be used on the flat medium to print the base layer, expanding layer pattern, and any additional layers with full printing quality. The expanding layer is only heated after printing is complete, allowing versatile standard printers to maintain high printing quality without requiring special equipment for irregular surfaces.
3Shape
If the expanding layer is expanded first, then the three-dimensional structure is formed, but subsequent printing quality deteriorates due to surface irregularity
Solution Approach 1:
The patent applies preliminary action by reversing the conventional sequence: instead of expanding the layer first and then printing, all printing operations are performed on the flat medium before the expanding layer is heated. The base layer, expanding layer with printed pattern, and additional layers are all prepared in sequence on the flat surface. Only after printing is complete is the expanding layer heated to form the three-dimensional structure, ensuring high printing quality is maintained.
4Productivity
If offset printing system is used on expanded surfaces, then high printing speed can be achieved, but the system cannot handle irregular surfaces
Solution Approach 1:
The invention resolves this contradiction by performing all printing operations before the expanding layer is heated and expanded. The medium remains flat during printing, allowing high-speed offset printing systems to operate at full capacity and achieve excellent printing quality. After all printing is complete, the expanding layer is heated to create the three-dimensional structure, thus enabling offset printing systems to maintain both high speed and surface compatibility.
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 approach enables enhanced-quality printing on expanded surfaces, reducing the time required for structure formation while maintaining the intended color tint, using standard printing systems.
Implementation Method 1
a photo-thermal conversion material formed on the medium
Implementation Method 2
the expanding layer is expanded, when heated
Data Source
AI summary
A structure forming apparatus includes a printing unit which prints a photo-thermal conversion material, a white material, and a coloring material in order on an expanding layer in an overlapping manner, where the expanding layer is expanded when heated with thermal energy of light. The apparatus also includes a heating unit which irradiates light on the expanding layer from a side of the coloring material to expand the expanding layer, and a controlling unit which sets a printing density of the photo-thermal conversion material lower by a level corresponding to a quantity of heat conducted from the coloring material than the printing density of the photo-thermal conversion material to be printed when the coloring material has no photo-thermal conversion characteristic in the case in which the coloring material has photo-thermal conversion characteristic, and prints the photo-thermal conversion material of the set printing density.