Inkjet Coating for Textured Surfaces
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Solution Overview
Problem
Current techniques for producing surface coatings on vehicle trim parts fail to achieve high color intensity, 3D effects, tactile relief, and resistance to scratching and abrasion, while being complex and expensive.
Innovation Solution
A process involving the successive deposition of alternating layers of a primer, varnish, adhesive, or coating agent and coloring substances in droplet form, followed by controlled drying and crosslinking, to create a textured surface with enhanced visual and tactile effects and mechanical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If current structured molding and coloring techniques are used, then surface texture and visual appearance are achieved, but the process becomes complex and expensive with limited color choices
Solution Approach 1:
The coating process is divided into multiple sequential layers, each deposited by independent inkjet print heads. This segmentation allows different substances (colorants, clear coats, textured layers) to be applied separately in controlled layers, enabling greater versatility in color and texture combinations without proportionally increasing overall process complexity
Solution Approach 2:
The inkjet printing system serves multiple functions: it deposits colorants, applies clear coats, creates textured surfaces, and forms protective layers all through the same deposition mechanism. This multi-functionality reduces device complexity compared to having separate systems for each coating function
2Reliability
If inkjet printing with transparent varnish layers is used, then some protection and raised layer effect are achieved, but color intensity and significant textured surface quality are not improved
Solution Approach 1:
The coating system uses composite material layers including colored inkjet deposits, clear coat varnish layers, and textured polymer layers. Each layer contributes specific properties: colorants provide visual appearance, clear coats provide protection and gloss, and textured layers provide tactile relief. The composite structure achieves both protection and high-quality visual/tactile effects simultaneously
Solution Approach 2:
The invention transitions from two-dimensional flat printing to three-dimensional textured surface formation by building up multiple layers with varying heights and profiles. The inkjet system deposits material that is then cured to form raised textured formations, adding the dimension of physical relief to the traditional flat printed surface
3Reliability
If multiple deposition techniques combining inkjet and PVD are used, then coating is achieved, but the process becomes complex and does not provide high quality textured surface resistant to mechanical aggressions
Solution Approach 1:
The invention changes the parameters of the inkjet printing process by using curable polymer-based substances that can be crosslinked through UV or other curing mechanisms. This parameter change (from conventional ink to curable polymer) transforms the deposited material into a durable, mechanically resistant coating while maintaining the simplicity of the inkjet deposition method
Solution Approach 2:
The invention replaces complex mechanical PVD deposition systems with an inkjet printing system that uses fluid deposition followed by curing. This substitution achieves similar protective coating results with significantly reduced device complexity by using programmable fluid ejection instead of complex vacuum-based physical vapor deposition 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 achieves high color intensity, pronounced 3D effects, and improved resistance to scratches, abrasions, and friction, with flexibility in design and cost-effectiveness.
Implementation Method 1
by means of a device (3) for depositing liquid substance in droplets (4; 5), in particular by jet
Implementation Method 2
followed by controlled drying and crosslinking
Implementation Method 3
followed by controlled drying and crosslinking
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2A~2D
AI summary
The present invention relates to a method for coating, optionally with specific colouring, an exposed surface of a body with simultaneous formation of a structured surface, including projecting formations, via a device for depositing one or more liquid substances in droplets, in particular by a jet, said method consisting, for each affected site (1") of the surface to be printed (1'), of consecutively depositing at least two vertically adjacent layers (6, 6') of a first substance selected from the group made up of a size, a varnish, an adhesion or attachment agent and a coating agent, preferably white or transparent and at least one second substance such as a colouring substance or a mixture of colouring substances, each of the consecutive layers (6, 6') being formed by depositing droplets (4, 4'; 5). The method is characterised in that it consists of consecutively depositing at least three vertically adjacent layers (6, 6') which are made up, alternatively, of a first substance and a second substance, each layer (6, 6') being made up of separate individual droplets (4, 4'; 5), arranged in each layer according to a predetermined pattern.