Textured Decorative Surfacing with Digital Image Compensation
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Solution Overview
Problem
Existing decorative surfacing materials fail to effectively combine aesthetic appeal with durability and cost-effectiveness, particularly in accommodating textured surfaces where digital printing struggles to maintain image quality due to variations in surface area.
Innovation Solution
A method involving the application of a textured layer on a substrate, followed by processing digital images to account for 3D surface variations, cross-correlating 3D models with digital data, and applying a UV-cured adhesion promoter and filler layers to ensure accurate and aesthetically pleasing digital printing, including a tie layer for improved ink adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If digital printing is applied directly to textured surfaces, then manufacturing process is simple, but image quality deteriorates due to surface area variations causing distortion and misalignment
Solution Approach 1:
The patent applies preliminary action by creating a 3D model of the textured surface and cross-correlating it with the digital image before printing. This pre-processing step compensates for surface area variations caused by the texture, allowing the printing process to account for the actual surface geometry and maintain image quality without requiring complex real-time adjustments during printing.
2Adaptability or versatility
If textured layer is applied to enhance aesthetic appeal, then decorative value is improved, but surface area variation increases causing printing alignment issues
Solution Approach 1:
The patent implements feedback by using the 3D model of the textured surface to inform and adjust the digital image processing. The cross-correlation between the 3D model and the digital image creates a feedback loop where the actual surface geometry is measured and used to compensate for its own effects on printing alignment, enabling both aesthetic texture and precise image placement.
3Ease of manufacture
If standard digital printing is used on textured surfaces, then equipment cost is low, but additional processing steps are required to maintain image quality
Solution Approach 1:
The patent replaces mechanical adjustment methods with computational processing. Instead of using complex mechanical systems to physically adjust the printing process for textured surfaces, the invention uses digital image processing and 3D modeling to compensate for surface variations, maintaining process simplicity while improving image quality through software-based solutions.
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 durable, customizable, and cost-effective digitally printed decorative surfacing materials that maintain image quality on textured surfaces by accurately compensating for surface area variations, reducing distortion and ink misalignment issues.
Implementation Method 1
applying a UV cured adhesion promoter layer prior to the step of applying the textured layer
Data Source
AI summary
A method for manufacture of a digitally printed decorative surfacing material includes applying a textured layer upon a substrate, processing a digital image to compensate for additional surface area provided by the textured layer so as to produce a resultant digital image, digitally printing the resultant digital image upon the textured layer, applying a top coat layer over the digitally printed image. A digitally printed decorative surfacing material in accordance with the method described above is also provided.