Deposition Substrate Level Differences for Controlled Flake Segmentation
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Solution Overview
Problem
Conventional methods for manufacturing pigment flakes result in irregularly-sized and shaped flakes with significant debris, including flake frames, which complicates the process and wastes material, particularly for applications requiring precise flake sizes and shapes.
Innovation Solution
A substrate with regions at different levels is used, allowing the coating to break along region borders into predetermined shapes, minimizing debris by using a substrate with level differences between abutting regions for controlled flake formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional random breakage method is used, then manufacturing process is simple, but flake shape and size are irregular and debris is generated
Solution Approach 1:
The substrate surface is segmented into multiple regions at different levels, with each region corresponding to a desired flake shape. This segmentation allows the coating to break along predetermined region borders, producing flakes of controlled shapes and sizes while minimizing debris generation.
Solution Approach 2:
The substrate is prepared in advance with regions at different levels before coating deposition. This preliminary structuring of the substrate creates predetermined break lines that guide the coating fragmentation process, ensuring that flakes break into desired shapes rather than random fragments.
2Manufacturing precision
If sieves are used to remove small flakes, then flake size quality is improved, but process complexity and material waste increase
Solution Approach 1:
The substrate is prepared in advance with regions at different levels before coating deposition. This preliminary structuring of the substrate creates predetermined break lines that guide the coating fragmentation process, ensuring that flakes break into desired shapes rather than random fragments.
Solution Approach 2:
The substrate surface is segmented into multiple regions at different levels, with each region corresponding to a desired flake shape. This segmentation allows the coating to break along predetermined region borders, producing flakes of controlled shapes and sizes while minimizing debris generation.
3Shape
If embossed frames are used to induce breaking, then flake shape is controlled, but significant debris in form of broken frames is generated
Solution Approach 1:
The substrate surface is segmented into multiple regions at different levels, with each region corresponding to a desired flake shape. This segmentation allows the coating to break along predetermined region borders, producing flakes of controlled shapes and sizes while minimizing debris generation.
Solution Approach 2:
Different regions of the substrate are given different levels to create specific break patterns. By varying the local geometry and height of substrate regions, the coating breaks into different shapes at different locations, optimizing flake shape control while eliminating frame debris.
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 produces pigment flakes with predetermined shapes and minimal debris, enhancing process efficiency and material utilization by ensuring flakes break along designed borders, reducing waste and complexity.
Implementation Method 1
for each two regions in an abutting relationship, a level of a first of the two regions is different from a level of a second of the two regions... breaking the coating along region borders into the pigment flakes
Data Source
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AI summary
A method of forming pigment flakes includes using a deposition substrate having a plurality of regions; some of the regions are raised or lowered so that there is a level difference between each two adjacent regions. A coating deposited onto this substrate breaks along region borders when it is separated from the substrate. In one embodiment, the substrate includes first and second regions, wherein each of the first regions is in an abutting relationship with at least one of the second regions. All the first regions are at a first level and all the second regions are at a second level, and the difference between the first and second levels is greater than a predetermined value. The first and second regions are preferably square-shaped regions for manufacturing square flakes with practically no debris.