Digital Printing and Embossing for Plastic Floor Pattern Alignment
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Solution Overview
Problem
Existing methods for forming plastic floor boards with stereoscopic patterns fail to accurately align the flat patterns on the printing layer with the stereoscopic patterns on the wear layer, resulting in a poor integral stereoscopic effect and limiting customization options.
Innovation Solution
A method involving digital printing, forming a protection layer, and creating a stereoscopic pattern using specialized machinery, ensuring accurate alignment and customization of patterns on plastic floor boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pre-printed patterns are roll-pressed into a whole with base layer and wear layer, then production efficiency is improved, but the flat pattern does not accurately correspond to the stereoscopic pattern resulting in poor integral stereoscopic effect
Solution Approach 1:
The pattern formation process is segmented into separate steps: first printing the flat pattern on the printing layer, then forming the stereoscopic pattern on the wear layer independently. This segmentation allows each layer to be processed separately with precise control, avoiding the alignment problems that occur when patterns are roll-pressed as a whole. The printing layer and wear layer are treated as independent components that can be precisely aligned through localized processing.
Solution Approach 2:
The flat pattern is pre-printed on the printing layer before the stereoscopic pattern is formed on the wear layer. This preliminary action establishes the base pattern that will later be aligned with the stereoscopic elements. By preparing the printing layer in advance with precise digital printing, the subsequent stereoscopic pattern formation can be accurately positioned relative to the pre-existing flat pattern, ensuring proper correspondence between layers.
2Ease of manufacture
If conventional roll-pressing method is used, then production process is simplified, but pattern customization is impossible
Solution Approach 1:
The pattern design is made dynamic and adjustable through digital printing technology. Instead of fixed patterns embedded in the roll-pressing mechanism, the printing layer can receive different digital patterns on demand. This allows the pattern design to be changed electronically without modifying the physical manufacturing process, enabling customization while maintaining a relatively simple manufacturing workflow. The system transitions from static, pre-configured patterns to dynamic, programmable patterns.
Solution Approach 2:
Pattern customization is achieved by changing the digital printing parameters rather than modifying the manufacturing equipment. The digital printing system allows variation in pattern design, color, and configuration through software control, enabling infinite pattern variations without changing the physical press or tooling. This parameter-based approach maintains manufacturing simplicity while providing full customization capability.
3Shape
If stereoscopic pattern is formed on wear layer, then aesthetic appeal is improved, but alignment with flat pattern on printing layer fails
Solution Approach 1:
The system incorporates feedback mechanisms to ensure accurate alignment between the flat pattern on the printing layer and the stereoscopic pattern on the wear layer. Digital printing technology provides precise positioning information that can be used to guide the stereoscopic pattern formation process. By using the printed pattern itself as a reference for alignment, the system achieves accurate correspondence between layers through feedback-based positioning and control.
Solution Approach 2:
The alignment mechanism replaces traditional mechanical registration systems with digital positioning and control. Instead of relying on mechanical features in the roll-pressing equipment to align patterns, the system uses digital printing coordinates and electronic control to position the stereoscopic pattern accurately over the flat pattern. This substitution of mechanical alignment with digital control achieves superior precision and flexibility.
Data Source
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AI summary
A method for forming stereoscopic patterns of plastic floor boards, comprising the steps of: step A: taking a base board, which has a blank or plain outer surface; step B: digital printing: positioning the base board on a digital printing unit, and using the digital printing unit to print the pigment on the outer surface of the base board according to the preset pattern, thereby forming a pattern layer, wherein the pattern of the pattern layer corresponds to or does not correspond to the stereoscopic pattern; step C: forming a protection layer: using a first forming unit to form a protection layer on the pattern layer with a transparent melt plastic raw material; step D: forming a stereoscopic pattern: using a second forming unit to form a stereoscopic pattern having a concave-convex structure on the protection layer. Through adopting the method of the present disclosure, various patterns may be designed and formed according to users' needs.