Multi-layered sheets suitable as floor of wall covering exhibiting a three-dimensional relief and a decorative image
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Solution Overview
Problem
Traditional methods for producing foamed vinyl floorings with embossed and printed patterns are limited by the need for expensive rolls with predetermined patterns, leading to potential errors and difficulty in changing designs, which restricts design variation and is suitable only for large production runs with repetitive designs.
Innovation Solution
A multi-layered sheet with a support layer, a foamed layer featuring a discontinuous chemically embossed relief pattern created by digitally printed foam inhibiting agent, and a decorative layer, allowing for independent control of embossing and decoration patterns using digital printing, enabling customizable designs without the need for expensive rolls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional rolls with predetermined patterns are used for embossing and printing, then production efficiency is maintained for large runs, but design flexibility and adaptability are severely limited
Solution Approach 1:
The patent uses digital printing to create precise copies of desired patterns directly on the foamable layer, eliminating the need for physical embossing rolls. The digital pattern data can be stored and reproduced exactly, providing design flexibility while maintaining consistent reproduction quality across production runs.
Solution Approach 2:
The patent replaces the mechanical embossing system (physical rolls) with a chemical embossing system using digitally printed foam inhibitors. This substitution eliminates the need for expensive, bulky physical rolls while achieving the same surface relief effects through controlled chemical foaming inhibition.
2Manufacturing precision
If expensive embossing rolls are used for each design, then consistent pattern quality is achieved, but manufacturing cost and device complexity increase significantly
Solution Approach 1:
Instead of creating expensive physical copies (rolls) for each design, the patent uses digital pattern data that can be stored and reproduced indefinitely without degradation. The digital printing process ensures consistent pattern quality while eliminating the need to manufacture, store, and interchange expensive physical rolls.
Solution Approach 2:
The patent replaces expensive, durable embossing rolls with inexpensive, consumable digital printing materials (foam inhibitor compositions). Each printing operation uses a small amount of material that is applied directly and consumed in the process, eliminating the need for costly roll manufacturing and maintenance.
3Adaptability or versatility
If multiple rolls are used consecutively to build up images, then design complexity increases, but registration errors and process complexity increase
Solution Approach 1:
The patent merges multiple printing operations into a single digital printing process. The digital printer can apply different pattern elements (embossing inhibitors and decorative images) in one coordinated operation, eliminating the need for multiple sequential rolls and their associated registration problems.
Solution Approach 2:
The patent replaces the mechanical multi-roll system with a digital printing system that uses non-contact deposition. This eliminates mechanical registration issues between rolls, as the digital printing process can precisely position different pattern elements based on digital coordinates rather than mechanical alignment.
4Adaptability or versatility
If rolls are interchanged to change designs, then design variety is achieved, but production time and operational complexity increase
Solution Approach 1:
The patent creates a dynamic system where design changes are achieved through software updates rather than physical roll changes. The digital printing system can instantly switch between different patterns by loading new digital files, allowing for rapid design variety without the time-consuming mechanical process of rolling changes.
Solution Approach 2:
The patent uses digital pattern copies that can be instantly reproduced without physical media changes. Instead of physically interchanging rolls, the system loads digital pattern data from storage, providing instantaneous design changes without the time loss associated with physical roll handling and installation.
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 allows for high-resolution, customizable three-dimensional surface relief and decorative images with unprecedented design freedom, reducing production errors and costs, and enabling production of unique designs without the limitations of traditional methods.
Implementation Method 1
a foamed layer having an upper surface and a lower surface, the lower surface of the foamed layer provided adjacent, and adherent to the upper surface of the support layer, the upper surface of the foamed layer comprising a discontinuous chemically embossed relief pattern
Implementation Method 2
Chemical embossing typically employs foaming inhibitor compounds, whereby selected areas of the surface of a foamable polymeric layer are printed with one or more ink compositions containing an agent that inhibits foaming when the material is subjected to a heat treatment. The foamable material is expanding fully in areas where no inhibitor is deposited, and foaming is reduced in areas with inhibitor
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
The present invention relates to a multi-layered sheet suitable as floor or wall covering exhibiting a three-dimensional surface relief and a decorative image, comprising: i. a support layer having an upper surface and a lower surface; ii. a foamed layer having an upper surface and a lower surface, the lower surface of the foamed layer provided adjacent, and adherent to the upper surface of the support layer, the upper surface of the foamed layer comprising a discontinuous chemically embossed relief pattern, wherein the discontinuous chemically embossed relief pattern comprises indentations formed by single or stacked dots of a digitally printed material comprising a foam inhibiting agent; and optionally iii. a decorative layer adhered to the upper surface of the foamed layer; and optionally iv. at least one wear resistant layer provided adjacent and adhered to the decorative layer; and optionally v. a backing layer provided adjacent and adhered to the lower surface of the support layer.