Multilayered Printed Matter Surface Planarity
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Solution Overview
Problem
Multilayered printed matters with two pattern layers and concealing layers can degrade in appearance and visual quality due to recessed parts forming on the outermost surface, affecting the attractiveness and visibility of patterns when light is applied from the back side.
Innovation Solution
Incorporating a protrusion-formed layer, such as a white ink layer, between the medium and the first pattern layer to fill recessed parts and planarize the surface, ensuring that recessed parts are not formed at irrelevant positions and improving the visual quality by preventing the pattern on the second layer from being visible from the front side when light is applied from the back side.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If concealing layers are formed between two pattern layers to conceal the pattern on one layer, then the pattern visibility control is improved, but recessed parts form on the outermost surface degrading appearance and visual quality
Solution Approach 1:
A protruding part is formed in advance in one of the print layers (either in the concealing layer or in a layer between the medium and the first pattern layer) before the final pattern layers are applied. This protruding part is positioned to fill any recessed parts that may form, ensuring surface planarity is maintained before the multilayered structure is complete.
Solution Approach 2:
The protruding part acts as an intermediary element between the recessed part and the outermost surface. It fills the recessed part and provides a planar surface for the subsequent pattern layers, thereby mediating between the structural requirement of concealing layers and the aesthetic requirement of surface flatness.
2Adaptability or versatility
If multiple print layers are stacked to create multilayered printed matter, then pattern visibility control and design flexibility are improved, but structural complexity increases
Solution Approach 1:
One of the print layers is designed to serve multiple functions: it acts as both a pattern layer (displaying visual information) and as a protrusion-formed layer (providing structural support to fill recessed parts). This multi-functionality reduces the need for separate dedicated structural layers, thereby simplifying the overall structure while maintaining design flexibility.
3Quantity of substance
If recessed parts are formed in print layers lacking effective pixels, then material usage is optimized, but surface irregularities degrade visual quality
Solution Approach 1:
The recessed parts that initially cause surface irregularities are converted into beneficial features by filling them with protruding parts from other layers. The hollow spaces that would otherwise create visual defects are transformed into structural elements that maintain surface planarity while still allowing reduced ink usage in areas lacking effective pixels.
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 solution enhances the appearance and visual quality of multilayered printed matters by preventing unwanted visibility of the second pattern layer from the front side, even when light is applied from the back side, and simplifies the structural complexity by eliminating the need for additional protrusion-formed layers.
Implementation Method 1
The print layers 103 to 106 are formed one by one by ejecting and curing UV-curable inks.
Data Source
Figure 1~2
Figure 3A~3D
Figure 4A~4D
AI summary
The object is to achieve improved appearance and visual quality of a multilayered printed matter formed of a plurality of print layers on a medium including two pattern layers having patterns printed thereon, and a concealing layer formed between the pattern layers. A multilayered printed matter (1) includes print layers (pattern layers) formed on a medium and having patterns printed thereon, and a concealing layer (10) interposed between the print layers. The concealing layer conceals the pattern printed on one of the pattern layers not to affect the pattern of the other pattern layer. The concealing layer is formed on the back side relative to the other pattern layer. The print layers between the medium and one of the print layers on the back side of the other pattern layer respectively have recessed parts (eg the black layer 5) recessed into their surfaces toward the back side. The back-side print layer (4, white) between the other pattern layers has a protruding part to fill one of the recessed parts and thereby planarize the surface of the back-side print layer.