Rubberized Roller Gravure Printing for Haptic Wood Surfaces
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Solution Overview
Problem
Existing methods for creating structured surfaces on material panels, such as wood-based panels, fail to replicate the natural tactile experience of real wood due to the smoothness of the top coat layer, which is not effectively structured in a continuous process, leading to a recognizable difference under backlighting and touch.
Innovation Solution
A method using a rubberized applicator roller with depressions corresponding to the desired structure, applying a paint structure to a non-structured top coat layer before it hardens, employing a direct gravure printing process to create a haptically perceptible surface that mimics natural wood surfaces by forming elevations corresponding to the depressions in the natural surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an embossing roller is used to create surface structure, then the surface structure can be applied, but the structure height is limited and cannot provide haptically perceptible relief
Solution Approach 1:
The patent inverts the conventional embossing approach by using a gravure printing method where depressions in the applicator roller transfer paint to form elevations on the surface. This inverse approach allows achieving greater structure heights (100-120 μm) that are haptically perceptible, overcoming the limitation of conventional embossing that produces only shallow structures.
2Manufacturing precision
If indirect gravure printing is used with a rubber blanket applicator roller, then paint structure can be applied, but the roller flattens the structure resulting in only 5 μm elevations
Solution Approach 1:
The patent changes the physical parameters of the applicator roller by using a rigid or semi-rigid material instead of soft rubber, and by controlling the metering gap and pressure conditions. These parameter changes prevent the flattening effect while maintaining continuous process capability, achieving elevations of 100-120 μm that are both manufacturable and haptically perceptible.
3Ease of manufacture
If the top coat layer is applied smooth and uniform, then the coating process is simple, but the surface lacks natural tactile properties
Solution Approach 1:
The patent applies the paint structure to the top coat layer before it fully hardens. This preliminary action allows the paint to be deposited and formed into the desired structure while the layer is still pliable, and then the layer is cured to lock in the structure. This approach maintains coating process simplicity while achieving natural tactile properties.
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 method produces a surface with a natural, irregular appearance and feel, enhancing the visual and haptic resemblance to natural wood, with lacquer structures of 100-120 μm height that are perceivable by touch, overcoming the limitations of previous techniques that could only achieve small elevations undetectable by touch.
Implementation Method 1
employing a direct gravure printing process to create a haptically perceptible surface
Data Source
Figure 1
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Figure 4
AI summary
The arrangement has a painting device (5) for applying a smooth, non-structured covering coat of paint to the board (8), an application roller (1) for applying a paint structure (10) to the covering coat, a dosing device (4) for dosing paint onto the roller and a transport device (12) for transporting the board from the painting device to the application roller. The application roller has a rubberized surface (3) with recesses corresponding to the paint structure to be applied for transferring paint from the dosing device to the cover coat.