Skateboard Manufacturing with Laser-Printed Patterns
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Solution Overview
Problem
Conventional skateboard manufacturing methods result in patterns that are not vibrant, prone to fading, and lack durability, while also failing to achieve a lightweight and cost-effective production process.
Innovation Solution
A method involving the use of an internal core board and surface boards made from foamed organic polymer materials, bonded with EVA resin, and featuring a laser-printed pattern protected by a polyurethane film, with additional plastic film reinforcement for enhanced toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional printing methods are used for skateboard patterns, then manufacturing cost is reduced, but pattern brightness, sharpness and vividness deteriorate
Solution Approach 1:
The patent replaces conventional mechanical printing methods with laser printing technology. The laser printing process uses laser beams to directly print patterns onto the skateboard surface, eliminating the need for traditional printing plates and mechanical pressure application. This substitution achieves superior pattern brightness, sharpness and vividness while maintaining cost-effectiveness through direct digital printing.
2Reliability
If conventional printing methods are used for skateboard patterns, then manufacturing process is simplified, but pattern durability and resistance to fading deteriorate
Solution Approach 1:
The patent replaces conventional mechanical printing with laser printing technology that directly deposits pattern material onto the skateboard surface. The laser printing process includes steps of applying primer treatment to PET film, performing laser embossing, vacuum-aluminizing, coating with polyurethane printing ink by gravure, and forming a protective film layer. This complex process sequence delivers superior pattern durability and fade resistance.
3Manufacturing precision
If foam molding is used for skateboard manufacturing, then production cost is reduced, but manufacturing precision and pattern quality deteriorate
Solution Approach 1:
The patent combines foam molding for the skateboard body with laser printing for pattern application. The foam molding process creates the basic skateboard structure at low cost, while the subsequent laser printing process applies high-precision patterns with superior brightness and sharpness. This hybrid approach maintains cost-effectiveness while achieving high pattern quality.
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 skateboards that are lightweight, durable, and have long-lasting, vivid patterns resistant to fading and wear, with a low production cost and improved handling characteristics.
Implementation Method 1
foaming an organic polymer material with steam with a temperature at a range of 160-180° C.
Implementation Method 2
sending the organic polymer material into an oven for heating to 190-210° C. to perform foam molding
Implementation Method 3
adhering the upper surface layer and the lower surface layer with the internal core layer together by EVA resin
Implementation Method 4
printing a pattern layer on a surface of the plate body by laser printing
Implementation Method 5
pressing by a press roll, wherein a pressing pressure is at a range of 0.8-1.2 MPa, a temperature of a pressure roller is at a range of 60-80° C.
Data Source
AI summary
A method for manufacturing a skateboard, includes steps of: foaming an organic polymer material with steam with a temperature at a range of 160-180° C. to produce a foam board as the internal core board; sending the organic polymer material into an oven for heating to 190-210° C. to perform foam molding; cutting the foam board into an internal core layer; cutting the foam board into an upper surface layer and a lower surface layer; and then adhering the upper surface layer and the lower surface layer with the internal core layer together by EVA resin, and wrapping the internal core layer between the upper surface layer and the lower surface layer; printing a pattern layer on a surface of the plate body by laser printing; and casting a layer of the plastic film.