Oblique Surface Structures for Defined Pigment Size and Shape
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Solution Overview
Problem
Existing pigment manufacturing processes, particularly those involving embossing, result in surface defects such as air bubbles and material displacement issues, which impair the optical quality and efficiency of the pigments produced.
Innovation Solution
A method involving the creation of a three-dimensional surface structure with obliquely sloping surface regions on a substrate, avoiding plane-parallel surfaces, which minimizes air bubble accumulation and material displacement, allowing for controlled breaking points to produce pigments of defined size and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If plane-parallel embossed structures are used to create predetermined breaking points, then pigment size and shape can be controlled, but air bubbles accumulate in the embossed areas causing surface defects that impair optical quality
Solution Approach 1:
The patent applies asymmetry by replacing plane-parallel embossed structures with obliquely sloping surface regions. The asymmetric slope geometry prevents air bubble accumulation that occurs in flat parallel structures, while still providing the necessary height offsets to create predetermined breaking points for controlled pigment fragmentation.
Solution Approach 2:
The patent uses curved or sloping surfaces instead of flat plane-parallel structures. The oblique slopes create a non-planar geometry that facilitates air bubble escape during embossing while maintaining the height differential needed for breaking point formation in the pigment layer.
2Manufacturing precision
If plane-parallel embossed structures are used, then breaking points are created for pigment production, but a large amount of material must be displaced during embossing which impairs embossing quality and can cause paint adhesion during demolding
Solution Approach 1:
The asymmetric oblique slope geometry reduces the volume of material that must be displaced during embossing compared to plane-parallel structures. The sloping surfaces allow material flow in a more natural direction, reducing embossing pressure requirements and minimizing the risk of paint adhesion during demolding.
Solution Approach 2:
The patent transitions from two-dimensional plane-parallel structures to three-dimensional obliquely sloping surface regions. This dimensional change allows the embossed structures to create breaking points through height offsets while displacing less material, improving both the embossing process and demolding characteristics.
3Ease of manufacture
If embossing processes are used to produce matrices, then surface structures are created for pigment formation, but surface defects arise that affect pigment optical properties
Solution Approach 1:
The asymmetric oblique slope design eliminates the air bubble trapping problem inherent in symmetric plane-parallel structures. The sloping geometry provides a natural path for air bubble escape during embossing, preventing the formation of surface defects that would compromise pigment optical quality.
Solution Approach 2:
The patent converts the potential harm of air bubble formation during embossing into a benefit by designing oblique slopes that actively guide air bubbles away from critical areas. The sloping surfaces use the air bubble rise tendency to their advantage, directing bubbles toward escape paths rather than trapping them in flat regions.
Data Source
Figure 1
Figure 2a~2b
Figure 2c
AI summary
The invention relates to a method for producing pigments having a defined size and shape and to pigments produced therewith. The method comprises the steps of: a) producing a three-dimensional surface structure (10; 100) on a substrate (11), wherein surface regions (12; 120) are formed, which each have a gradient that extends obliquely with respect to a base level (N) of the surface structure and which are arranged in columns (14, 15; 140, 150) that are offset to one another; b) applying a pigment material layer (19) onto the surface structure; c) detaching the pigment material layer (19) from the surface structure and producing the pigments.