Structured Varnish Surface via Applicator Roll Transfer

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for producing structured, optically transparent varnish surfaces on wood material boards are costly and time-consuming, particularly when switching between different decorations and surface structures, and are prone to digital print head collisions due to unevenness in the boards.

Innovation Solution

Applying transparent varnish to an applicator roll with digitally controlled nozzles that transform the varnish into a structured distribution, which is then transferred to the substrate board, using a smooth standard applicator roll and digitally controlled gas or compressed air nozzles to create a continuous, non-repetitive three-dimensional surface structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If digitally controlled nozzles are arranged at a short distance above the board-shaped workpiece to apply varnish directly, then productivity and resolution are improved, but the risk of collisions with uneven surfaces increases

Engineering Contradiction:

Improveprint speedVSAvoidcollision risk

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent introduces an applicator roll as an intermediary component between the nozzles and the workpiece. The nozzles apply varnish to the applicator roll, which then transfers the varnish to the board-shaped workpiece through contact. This mediator approach allows the nozzles to be positioned at a safe distance from the workpiece surface, eliminating collision risk while maintaining the ability to produce high-resolution structured varnish surfaces.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If structured pressing plates, belts or rolls are used to produce surface structures, then manufacturing precision is improved, but device complexity and production costs increase

Engineering Contradiction:

Improvesurface structure precisionVSAvoidproduction complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent uses the applicator roll as a temporary copy medium. The structured varnish pattern is first created on the applicator roll surface through digital nozzle control, then this pattern is transferred to the workpiece. This copying approach eliminates the need for permanently structured pressing plates or rolls, reducing device complexity and costs while maintaining manufacturing precision.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent changes the state of the applicator roll from a permanently structured component to a temporarily patterned one. By controlling the varnish application parameters digitally through nozzles, the surface structure can be varied without changing physical components, thereby reducing device complexity and enabling flexible production.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If structured varnish applicator rolls are used to produce three-dimensional surface structures, then manufacturing precision is improved, but adaptability decreases due to time-consuming changes

Engineering Contradiction:

Improvesurface structure precisionVSAvoidflexibility to change decorations

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent introduces dynamic control through digitally controlled nozzles that can be programmed to create different varnish patterns on the applicator roll. This dynamic digital control system replaces static physical structures, allowing rapid adaptation to different decorations and surface structures without time-consuming physical changes, thereby improving both adaptability and maintaining manufacturing precision.

Inventive Principle:

Principle #15Dynamics

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 reduces costs by using a standard applicator roll and minimizes the risk of print head collisions, enabling the production of unique, high-resolution three-dimensional surface structures that match decorative images, with improved maintenance and higher print speeds compared to conventional varnish jet print heads.

Implementation Method 1

the print heads operate according to a jet printing method known from ink-jet printers

Methodology Applied

Scientific EffectJet printing: Jet

Implementation Method 2

said applicator roll transfers the varnish to the surface of the substrate board having a decoration

Methodology Applied

Scientific EffectRoller transfer: Roller

Data Source

PatentUS9782797B2Method and device for producing a structured varnish surface

Publication Date: 2017.10.10 FRITZ EGGER GMBH & CO OG

AI summary

The invention relates to a method for producing a structured, at least partly optically transparent varnish surface on a surface of a substrate board, preferably of a wood material board, having a decoration. The steps of the method include applying a transparent or at least partly transparent varnish to an applicator roll thereby producing a structured varnish surface and transferring the structured varnish surface to a substrate board having a decoration. The varnish is applied to the applicator roll by a plurality of digitally controlled nozzles in a distribution defining a structure and/or is transformed on the applicator roll into a distribution defining a structure. Furthermore, a device for carrying out the method is described.