Digital Embossing via Liquid B Removal for Surface Structures
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Solution Overview
Problem
Current digital printing methods for creating three-dimensional surface structures on substrates face challenges in achieving precise embossing in registration with the printed image, especially when using varnishes containing anti-abrasive fillers like aluminum oxide, and are limited to photo-crosslinking varnishes, making it difficult to efficiently and cost-effectively reproduce natural materials such as wood and stone.
Innovation Solution
A method involving the application of a liquid B on a partially solidified resin A, followed by simultaneous polymerization and subsequent removal of the polymerized liquid B, which is more brittle, allowing for the creation of a three-dimensional structure that matches the printed image while maintaining the chemical-physical properties of the resin A.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional embossing methods with molds and rollers are used, then three-dimensional surface structures can be produced, but it is difficult to achieve precise registration with the printed image and requires multiple molds for different structures
Solution Approach 1:
The invention uses a digital copy of the surface structure (obtained from 3D scanning) to directly guide the embossing process through digital printing of liquid B, eliminating the need for physical molds and achieving precise registration with the printed image through digital file matching
Solution Approach 2:
The invention replaces the mechanical mold system with a digital printing system that deposits liquid B according to digital data, substituting complex mechanical alignment with digital file-based registration
2Adaptability or versatility
If photo-crosslinking varnishes are used for embossing, then three-dimensional structures can be formed, but the method is limited to photo-crosslinking varnishes and cannot be applied to other types of varnishes containing anti-abrasive fillers
Solution Approach 1:
The invention creates a universal embossing method that works with multiple types of varnishes (photo-crosslinking, epoxy, polyurethane, hot-melt) by using a通用的 liquid B composition that can be applied to and removed from different resin systems without compromising their chemical-physical properties
Solution Approach 2:
The invention extracts the embossing function from the varnish chemistry itself by introducing a separate liquid B component that provides the embossing structure independently, allowing the varnish to maintain its original properties while gaining embossing capability
3Productivity
If digital printing is used to apply liquid B on resin A, then efficient and economical reproduction of three-dimensional structures is achieved, but the liquid B must be removable after polymerization
Solution Approach 1:
The invention applies the principle of discarding by designing liquid B to be intentionally removable after serving its embossing function, using its brittleness to facilitate easy removal while maintaining the integrity of the resin A structure during the process
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 efficient and economical reproduction of three-dimensional surface structures in register, providing the desired resistance and hardness, and can be applied to various substrates, including those with anti-abrasive fillers, offering flexibility and precision in digital printing.
Implementation Method 1
B) applying a liquid B on at least one portion of the resin A, when the resin A is liquid or partially solidified C) polymerizing, also separately, the resin A and the liquid B; D) removing the polymerized liquid B
Data Source
AI summary
A method and related apparatus for generating a surface structure includes the steps of: (A) applying a resin A on the surface of a material; (B) applying a liquid B on at least one portion of the resin A, when the resin A is liquid or partially solidified; (C) polymerizing, also separately, the resin A and the liquid B; and (D) removing the polymerized liquid B.