Sheet Goods Print Repeat Length and Pattern Variety
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Solution Overview
Problem
Current methods for producing surface coverings like tiles and sheet goods with printed patterns face limitations in pattern variety and repeat length, resulting in easily recognizable repeat patterns when installed, which can be aesthetically undesirable and limit design options.
Innovation Solution
The method involves using at least two printers with different repeat lengths, such as rotogravure, flexographic, and offset lithography, to print patterns on separate films or the same substrate, allowing for the creation of surface coverings with extremely long repeat lengths and numerous unique tile patterns by varying the circumference of the print cylinders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If print cylinders with the same repeat length are used to ensure sharpness and clarity, then printing precision is improved, but the number of different tile patterns is limited to 6 or 9
Solution Approach 1:
The patent changes the parameter of repeat length from being uniform across all print cylinders to being different for each print cylinder. Specifically, it uses print cylinders with repeat lengths of 24 inches, 36 inches, and 48 inches respectively, allowing the production of up to 216 different tile patterns (6×6×6) while maintaining sharp and clear printing through proper alignment of the different repeat length cylinders
2Manufacturing precision
If print cylinders with circumference of 24 or 36 inches are used, then printing precision is maintained, but the repeat length of sheet goods is short (24 or 36 inches)
Solution Approach 1:
The patent merges multiple print layers with different repeat lengths (24 inches, 36 inches, and 48 inches) onto a single sheet good. By combining these different repeat length patterns in a laminated or co-printed structure, the effective repeat length becomes the least common multiple of all individual repeat lengths, which is 144 inches (12 feet), thereby extending the repeat length while maintaining printing precision
3Adaptability or versatility
If multiple print layers with different repeat lengths are used to increase pattern variety, then the number of different tiles increases, but the device complexity increases
Solution Approach 1:
The patent makes the printing system multi-functional by enabling a single printing apparatus to handle multiple repeat length configurations (24 inches, 36 inches, and 48 inches) through the use of different print cylinders. This universal approach allows the system to produce up to 216 different tile patterns without requiring entirely separate printing lines, thereby managing device complexity while maximizing pattern variety
Data Source
AI summary
Sheet goods having extremely long repeat lengths and tiles having a large number of different visual patterns are formed by printing two different print patterns having different repeat lengths. The two different print patterns are printed on two films that are laminated together, or on a substrate, or one print pattern on a substrate and one print pattern on a transparent or translucent film that is laminated to the printed substrate.