Optical Defect Concealment via Digital Surface Imitation Transfer

Solution Overview

Problem

Concealing optical defects on surfaces, such as scratches and dents, is challenging due to the need for skilled specialists and time-consuming manual techniques, especially for large, fixed surfaces like aircraft cabin interiors, where complete replacement is not feasible.

Innovation Solution

A method involving digital recording of the defect and surrounding surface, image processing to create a surface imitation, printing this imitation onto a transfer film, soaking and activating the ink, aligning and applying the transfer film to the surface, and peeling it off to leave a matching ink pattern, followed by a protective layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual decorative painting techniques are used to conceal optical defects, then high-quality concealment can be achieved, but the process becomes time-consuming and requires skilled specialists

Engineering Contradiction:

Improveconcealment qualityVSAvoidrepair time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent creates a digital copy of the surrounding surface pattern and applies it to the defect area. A digital image of the surrounding surface is captured, processed to generate a pattern matching the original surface, and transferred to the defect location, eliminating the need for manual copying by specialists while maintaining high concealment quality

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the manual mechanical process of decorative painting with an automated digital system. Instead of skilled specialists manually painting patterns, the system uses digital image capture, computer processing, and automated transfer to apply the concealing pattern, significantly reducing time and skill requirements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If manual decorative painting techniques are used to conceal optical defects, then high-quality concealment can be achieved, but the process becomes cost-intensive due to the need for specialized skills

Engineering Contradiction:

Improveconcealment qualityVSAvoidrepair cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent creates a digital copy of the surrounding surface pattern and applies it to the defect area. A digital image of the surrounding surface is captured, processed to generate a pattern matching the original surface, and transferred to the defect location, eliminating the need for manual copying by specialists while maintaining high concealment quality

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the manual mechanical process of decorative painting with an automated digital system. Instead of skilled specialists manually painting patterns, the system uses digital image capture, computer processing, and automated transfer to apply the concealing pattern, significantly reducing time and skill requirements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If complete replacement of damaged surfaces is performed, then visual quality is restored, but it is not feasible for large, fixed surfaces

Engineering Contradiction:

Improvesurface qualityVSAvoidsurface area

Core Design Contradiction:

Manufacturing precisionVSArea of stationary object

Solution Approach 1:

The patent divides the surface treatment into two segments: the damaged area requiring repair and the surrounding intact surface. By capturing and replicating only the pattern from the surrounding area onto the defect, the system treats the damaged segment locally without needing to replace the entire surface, making large surface repairs feasible

Inventive Principle:

Principle #1Segmentation

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 allows for high-quality concealment of optical defects without requiring specialized skills, enabling rapid scaling and increased availability of repairs for both patterned and monochromatic surfaces, including wood with visible grain, and accounts for color deviations over time.

Implementation Method 1

soaking of the transfer film in order to partially dissolve the ink applied onto the film

Methodology Applied

Scientific EffectDissolution: Solvation

Implementation Method 2

application of an activator onto the printed side of the transfer film in order to make the ink tacky and/or onto the surface in order to bond the ink thereto

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS12059878B2Method for concealing optical defects in surfaces

Publication Date: 2024.08.13 LUFTHANSA TECHNIK AG

AI summary

A method conceals optical defects in surfaces. The method includes: obtaining a digital image by a digital optical recording the optical defect and a surrounding surface; obtaining an imitation of the surface in a region of the at least one optical defect by image processing of the digital image; printing a mirror-inverted, true-to-scale representation of the surface imitation onto a transfer film; soaking the transfer film; applying an activator onto a the transfer film or onto the surface; aligning the transfer film onto the surface so that the surface imitation on the transfer film coincides with the optical defect on the surface; pressing the transfer film onto the surface; peeling the transfer film from the surface; pressing on the ink remaining on the surface; and after complete drying of the activator and of the ink: applying a protective layer onto the surface imitation.