Textured Display Sheet Printing Without a Protective Layer
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Solution Overview
Problem
Conventional display sheets for outdoor floor surfaces require a protective layer for durability and slip resistance, increasing production costs and complexity, while omitting this layer compromises wear and slip resistance.
Innovation Solution
A display sheet with a sailcloth substrate having specific surface projections and depressions, where a fine ink permeates the depressions to form a durable ink layer protected by the projections, eliminating the need for a protective layer and enhancing wear resistance and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective layer is coated on the printed surface to enhance wear resistance and damage resistance, then the mechanical durability is improved, but the number of operation steps increases and the unit cost increases
Solution Approach 1:
The patent combines the protective layer function with the printed surface itself by forming a protective layer that is integrated with the ink layer. The protective layer is formed simultaneously with the printing process or in a combined operation, eliminating the need for separate coating steps while maintaining wear resistance and damage resistance.
Solution Approach 2:
The printed surface is designed to serve multiple functions: it provides both the visual information display and the protective function. By using the ink layer itself as part of the protective system or by integrating the protective layer with the printing process, the system achieves both information transmission and mechanical protection without requiring separate dedicated protective components.
2Reliability
If a protective layer is coated on the printed surface to enhance wear resistance and damage resistance, then the mechanical durability is improved, but the unit cost increases
Solution Approach 1:
The protective layer formation is merged with the printing operation, allowing both functions to be achieved in a single integrated process. This combination eliminates the need for separate coating equipment, materials, and labor, thereby reducing the unit cost while maintaining the protective function.
Solution Approach 2:
The printing process is designed to create a multi-functional layer that serves both as the visual display medium and as the protective barrier. By making the ink layer itself partially protective or by integrating protective materials into the printing process, the system achieves dual functionality without requiring additional manufacturing steps or materials, thus reducing unit cost.
3Device complexity
If the protective layer is omitted to reduce operation steps and cost, then the manufacturing complexity is reduced, but the wear resistance and damage resistance of the printed surface degrade
Solution Approach 1:
The protective function is merged into the printing process itself. The ink layer is formulated or applied in such a way that it provides both the visual information and the protective barrier, or the protective layer is formed as an integrated part of the printing operation, eliminating separate coating steps while maintaining wear resistance.
Solution Approach 2:
The printed surface is designed to perform multiple functions simultaneously. The ink layer serves both as the visual display medium and as the protective barrier against wear and damage. This multi-functional design eliminates the need for separate protective layers while maintaining the required durability.
4Device complexity
If the protective layer is omitted to reduce operation steps and cost, then the manufacturing complexity is reduced, but the surface-slip resistance degrades
Solution Approach 1:
The slip resistance function is merged with the printed surface by formulating the ink layer or the integrated protective layer with slip-resistant properties. The same layer that provides visual information and mechanical protection also provides the necessary surface friction for safety, eliminating the need for separate slip-resistant coatings.
Solution Approach 2:
The printed surface is designed to provide multiple functions in a single layer: visual display, mechanical protection, and slip resistance. By incorporating slip-resistant materials or surface characteristics into the ink layer or integrated protective layer, the system achieves all three functions without requiring separate dedicated layers, thus reducing manufacturing complexity while maintaining safety.
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 display sheet maintains visibility and durability without a protective layer, allowing easy peeling from surfaces without breakage and reducing production costs, while maintaining slip resistance and durability.
Implementation Method 1
an ink layer formed by causing a fine ink to cover the projections and permeate the depressions
Data Source
AI summary
A display sheet includes a substrate; front-side and rear-side synthetic resin composition layers formed on front and rear surfaces, respectively, of the substrate; and an ink layer formed by ink-jet on the front-side synthetic resin composition layer. The substrate is made of sailcloth having projections and depressions on front and rear surfaces thereof. A surface of the front-side synthetic resin composition layer is formed on an irregular surface having projections and depressions attributed to the projections and depressions of the surface of the substrate. The ink layer is formed by causing a fine ink to cover the projections and permeate the depressions.