Multi-Layer Coating Gloss Control via Digital Print Head
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Solution Overview
Problem
Existing methods for adjusting the gloss value of coated surfaces, such as plate-shaped workpieces, lack sufficient variability and repeatability in achieving desired optical effects.
Innovation Solution
A method involving multiple layers of coating material with specific patterns, including gaps for undirected light refraction, applied using a digital print head, where each layer's characteristics like droplet size, spacing, and voltage pulse shape are adjusted to achieve a continuous and targeted gloss value, allowing for the creation of varying gloss levels and optical effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single layer of coating material is applied with a defined pattern, then a specific gloss value can be achieved, but the variability and continuous adjustability of gloss values is insufficient
Solution Approach 1:
The coating is divided into multiple layers (at least two layers) with different patterns, where each layer contributes differently to the overall gloss effect. This segmentation allows independent optimization of each layer's pattern characteristics to achieve varied gloss values.
Solution Approach 2:
The solution transitions from a single-layer approach to a multi-layer approach, adding the dimension of layer stacking. This enables continuous adjustment of gloss values by varying the number of layers, their individual patterns, and their combinations, providing finer control over the final optical appearance.
2Illumination intensity
If the pattern comprises gaps in the coating to cause undirected light refraction, then scattered light effect is achieved, but the complexity of controlling gloss value increases
Solution Approach 1:
Different regions of the coating (different layers) are given different pattern qualities - each layer can have its own specific gap size, spacing, and distribution characteristics. This local differentiation allows tailored light refraction effects in each layer while maintaining overall pattern control through systematic parameter variation.
Solution Approach 2:
The pattern characteristics (gap size, spacing, distribution) are controlled by adjusting ejection parameters such as droplet size, spacing, and voltage pulse characteristics. By changing these parameters systematically across multiple layers, the light refraction effect is optimized without requiring complex device modifications.
3Adaptability or versatility
If multiple layers with different patterns are applied, then continuous adjustment of gloss value is enabled, but the number of coating steps increases
Solution Approach 1:
The multiple layers are applied in a continuous coating process without interrupting the workflow. The patterned coating material is ejected sequentially to form multiple layers in succession, maintaining continuous production flow while achieving the desired multi-layer structure for gloss control.
Solution Approach 2:
The pattern characteristics of each layer are predetermined through setting the ejection parameters (droplet size, spacing, voltage pulse) before coating begins. This preliminary configuration allows the multi-layer gloss adjustment to proceed systematically without requiring complex real-time adjustments during the coating 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
Enables precise and repeatable adjustment of gloss values, allowing for the production of grains with different gloss levels and depth effects, enhancing the optical appearance and adaptability of coated surfaces.
Implementation Method 1
producing a coating on the surface of the object to be coated by means of a coating head that comprises a plurality of outlets for the coating material
Implementation Method 2
a defined pattern is applied in layers to the surface to be coated. This pattern comprises gaps in the coating that cause undirected light refraction (scattered light)
Implementation Method 3
gaps in the coating that cause undirected light refraction (scattered light)
Data Source
AI summary
The invention relates to a method and a device for coating a surface of an object, in particular a narrow side of a plate-shaped workpiece. The device and method can be used, for example, in the field of the furniture and components industry.