Gloss-Differentiated Surface via Intermediate Layer Absorption
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Solution Overview
Problem
Existing methods for creating surfaces with varying gloss levels on panel-shaped workpieces, such as those imitating natural wood or stone, face limitations in achieving significant differences in gloss levels using conventional printing techniques, particularly due to the residual film from gravure printing processes that alter the gloss of the sealing layer.
Innovation Solution
Applying a partially transparent intermediate layer over the sealing layer before printing the design varnish wet-on-wet, where the intermediate layer is made of the same material as the sealing lacquer, absorbs residual film and maintains the original gloss level of the sealing varnish, allowing for a substantial difference in gloss levels between the printed image and the surrounding surface, achieved by optimizing the application quantities of the intermediate and design varnishes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a design print is applied directly to the sealing layer using conventional gravure printing, then the production process is simple and efficient, but the residual film from printing alters the gloss level of the sealing layer, preventing significant gloss level differences
Solution Approach 1:
An intermediate layer is introduced between the sealing layer and the design print. This intermediate layer acts as a mediator that receives the design print with its residual film while protecting the sealing layer's original gloss level. The intermediate layer is applied in a wet state during wet-on-wet printing, allowing it to absorb the residual film and prevent it from affecting the sealing layer's surface properties.
Solution Approach 2:
The surface structure is segmented into three distinct layers: the sealing layer, the intermediate layer, and the design print. This segmentation allows each layer to perform its specific function independently - the sealing layer provides the base gloss level, the intermediate layer manages the printing residual film, and the design print provides the visual design with its own gloss characteristics.
2Manufacturing precision
If three-dimensional structures are created to achieve varying gloss levels, then significant gloss differences can be achieved, but the process consumes excessive energy and time for curing
Solution Approach 1:
Instead of creating physical three-dimensional structures that require extensive curing, the invention uses a two-dimensional intermediate layer that optically simulates the effect of three-dimensionality through gloss level variations. The intermediate layer is applied as a thin film that, when combined with the design print, creates the visual perception of depth and surface variation without the energy-intensive curing process required for thick three-dimensional structures.
3Quantity of substance
If the sealing layer is made highly transparent to show the decorative layer, then the visual effect is enhanced, but the natural appearance is reduced due to uniform gloss
Solution Approach 1:
The surface is given non-uniform local qualities through the intermediate layer and design print combination. Different regions of the surface exhibit different gloss levels - some areas maintain the high gloss of the sealing layer while others show the lower gloss of the design print. This local variation in gloss quality creates natural-looking variations that enhance the perception of depth and realism while preserving the transparency of the sealing layer.
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 enables the production of panel-shaped workpieces with gloss level differences of at least 50 gloss units, providing enhanced optical effects suitable for decorative applications without altering the haptic properties, and is more energy-efficient compared to creating three-dimensional structures.
Implementation Method 1
Applying a partially transparent intermediate layer over the sealing layer before printing the design varnish wet-on-wet, where the intermediate layer is made of the same material as the sealing lacquer, absorbs residual film and maintains the original gloss level of the sealing varnish
Data Source
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AI summary
The present invention relates to a method for producing a surface with gloss levels on a plate-shaped workpiece, comprising the following process steps: - providing a substrate 1, in particular a wood-based material substrate, - indirect or direct printing of the substrate 1 with a decorative layer 3, - full-surface application of an at least partially transparent sealing layer 4 to the decorative layer 3, wherein the sealing layer 4 consists of a sealing lacquer which, after curing, has a first gloss level, - at least partial curing of the sealing layer 4, - indirect or direct printing of the at least partially cured sealing layer 4 with a design print 6, which is formed with an at least partially transparent design lacquer which, after curing, has a second gloss level.wherein – after at least partial curing of the sealing layer 4, an at least partially transparent intermediate layer 5 is applied over the entire surface of the sealing layer 4, and the intermediate layer 5 is produced with an intermediate lacquer that consists of the same material as the sealing lacquer or of a material that, after curing, has a similar gloss level to the sealing lacquer, – and wherein the design lacquer is printed wet-on-wet onto the intermediate layer 5 before the intermediate layer 5 has cured. The invention further relates to a plate-shaped workpiece with a surface produced in this way and to a system for carrying out the method.