3D Structured Component Coloring via Digital Printing

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Solution Overview

Problem

Current methods fail to economically produce three-dimensionally structured components with free-form surfaces that accurately integrate color information matching the structural information, often resulting in inferior quality due to issues like planar surface treatments, multiple layers, and deformation during deep drawing and back-injection molding.

Innovation Solution

A method involving non-contact digital printing to apply three-dimensional color information divided into surface elements, with heavier application on sloping elements, followed by deep-drawing and back-injection molding, using a structured film that can withstand deformation and maintain microstructured surfaces, allowing for precise color and structural alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If color layer is applied to deep-drawn foil, then component can be produced, but quality is lost due to microstructure closure and deformation

Engineering Contradiction:

Improvecomponent productionVSAvoidmicrostructure quality

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The color layer is applied to the foil surface before deep-drawing and back-injection molding. The foil is first provided with a structured surface, then the color-carrying layer is applied to match the three-dimensional structure, and only then are the deep-drawing and molding operations performed. This preliminary coloring prevents microstructure closure and maintains quality throughout the forming process.

Inventive Principle:

Principle #10Preliminary action

2Loss of information

If film is printed then embossed, then color information is provided, but precision is lost due to uncontrolled flow during forming

Engineering Contradiction:

Improvecolor information accuracyVSAvoidcolor-structure alignment

Core Design Contradiction:

Loss of informationVSManufacturing precision

Solution Approach 1:

The color-carrying layer is applied to the foil in advance, matching the three-dimensional structured surface before any forming operations. This preliminary action ensures that color information remains precisely aligned with the structural information throughout subsequent deep-drawing and molding processes, eliminating uncontrolled flow and precision loss.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If strong aspect ratios are used in three-dimensional structure, then design freedom is improved, but quality is lost due to high temperatures and pressures

Engineering Contradiction:

Improvedesign freedomVSAvoidsurface quality

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The color layer is applied to the foil before deep-drawing operations that create strong aspect ratios. By performing the coloring action in advance, the method protects the color information from degradation due to high temperatures and pressures during forming, maintaining surface quality while enabling design freedom.

Inventive Principle:

Principle #10Preliminary action

4Ease of manufacture

If paint layer is applied after structuring, then coloring is possible, but microstructures are closed or smoothed out leading to loss of matt/glossy effects

Engineering Contradiction:

Improvecoloring capabilityVSAvoidmicrostructure surface

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The color-carrying layer is applied to the foil surface while the microstructured three-dimensional structure is already present. This preliminary coloring action occurs before any forming operations that could close or smooth out microstructures, thereby preserving matt/glossy effects based on light refraction in the microstructure while still enabling comprehensive coloring.

Inventive Principle:

Principle #10Preliminary action

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 enables the production of components with photorealistic images and functional layers that maintain the three-dimensional structure and microstructured surfaces, avoiding quality loss and deformation, and allows for easy demolding and reuse of the structured film.

Implementation Method 1

application of the three-dimensional color information divided into surface elements to the structured surface using a non-contact digital printing process

Methodology Applied

Scientific EffectNon-contact digital printing:

Implementation Method 2

deep-drawing the remaining at least one coloring layer... the structured film that can withstand deformation and maintain microstructured surfaces

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentEP2160276B1Method for producing coloured, three-dimensionally structured components with free-form areas

Publication Date: 2012.04.04 SAUERESSIG KILIAN

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AI summary

A method for producing coloured, three-dimensionally structured components with free-form areas, having the following steps: provision of a structured surface (10, 140); application of the three-dimensional colour information to the structured surface (10, 140) by means of a non-contacting digital printing process as at least one inking layer (20), wherein ink is applied more strongly, corresponding to the inclination, to inclined surface elements of the three-dimensional structure on at least one of the inking layers than on planar surface elements; drying of the at least one inking layer (20); pulling off the inking layer (20) from the structured surface (10, 140); thermoforming of the remaining at least one inking layer (20); and spraying of a shaping compound behind the thermoformed at least one inking layer (20).