Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02614613 2007-12-21 2 I DESCRIPTION BACKGROUND OF THE INVENTION TECHNICAL FIELD The invention relates to printed stonewall panels and methods for the three- dimensional (3D) reproduction of the image via two-dimensional (2D) printing techniques onto a non-uniform irregular planar surface created via the transmission of said 3D information to specific machineries onto a specified substrate. The invention also relates to a list of substrate materials that present specific physical and chemical attributes needed to support this invention. Typical dimensions of the printed substrate range from a few square feet (few square meters) to over 500 square feet (50 square meters) covering external or internal applications. BACKGROUND ART A conventional technique to create the perception of 3D imagery on a 2D support is to first print the image on a uniform planar surface then emboss the surface via mechanical means. This technique is widely covered by U.S. Publication No. US2003/0056885 and U.S. Publication No. US2004/0261639 and more recently in U.S. Publication No. US2005/0035488. The regular & constant aspect of the non-planar surface allows to present in one axe the longitudinal displacement of the printing heads. This technique is covered by, U.S. publication No. 2003/0001941 where the regular and constant non-planar object consists of a pre-embossed plastic card with a relatively small printing area. Other techniques use mechanical means to rotate a uniform, non-planar object under the printing heads presenting a constant 2D surface to the printing heads. U.S. patent No. 6,923,115 covers these techniques where the uniform, non-planar object consists of a sports ball of various dimensions. A key feature of this invention is the method used to print on large non- uniform irregular planar surface. As presented above, previous inventions disclose techniques to print either on regular non-planar surfaces or uniform non-planar surfaces but not on large non- uniform irregular surfaces in both axes. PCT publication No. WO 02/18148 Al presents an apparatus to print on a non-planar and non-uniform surface, but restricted to only one axis. No physical correlation between the image contour lines and the substrate relief exists. For example, printing on a rough surface such as fabric does not require any physical correlation. Whereas in this new proposed process a highly precise correlation (called registration in the printing industry) is required between the printed image and it's non-planar substrate to emphasize on the 3D aspect of the product. There is a growing need for printing large images on a substrate in relief. For a one- time custom printing, the proposed process would use a numerically controlled milling machine (router) to engrave the relief into the substrate then print the image. None of the CA 02614613 2007-12-21 3 previously described techniques combine the retrieval and transmission of 3D information from a photograph to an engraving process through printing techniques. I For high speed printing, U.S. patent No. 6,460,958 covers nozzle design and angulations to print on 3D objects but does not address any registration techniques at any point in the patent. Similarly, U.S. patent No. 6,755,518 covers how the print heads may be independently moveable to control the spacing of the print heads from the substrate surface. Whereas, as stated above, in this newly proposed process, a highly precise correlation is required between the printed image and it's non-planar substrate to emphasize the 3D aspect of the product. In addition, , this new proposed process uses motionless print head. Therefore no angulations or spacing adjustments are required. For high volume, repeat-pattern printing of the engraved substrate is replaced by a pre- formed substrate manufactured in series. U.S. publication No. 2003/0001941 discloses a technique where the printed substrate consists of a pre-embossed plastic card. There are a few issues with this pre-embossed plastic card: Firstly, this pre-embossed plastic card covers a much smaller printing surface than the techniques described in this invention. Secondly the relief pattern is symmetric to the printing axis, which restricts considerably the relief pattern. The proposed invention would support a much wider variety of relief patterns as well as of printing patterns. SUMMARY OF THE INVENTION The present invention seeks to eliminate or at least mitigate the disadvantages of the prior art and has for objective to provide a reproduction system of photographic images by interpreting the 3D information therein and then transferring the image and relief onto a substrate via data transfer process combined with machining processes and 2D printing techniques results in a 3D, non-uniform, irregular, non-planar physical representation of the original photographic representation. To this end, the printing system consists of: - An optical mean of interpreting the three dimensional information from the photographic image. - A numerically controlled engraving/milling machine (router) to transfer the 3D elements of the image onto a substrate. - A high precision, large surface, printing machine. - A high precision registration and positioning means for printing the said image on the said engraved substrate. All of which would result in a 3D representation of the original photographic image. The engraving/milling machine will function by following the interpretation of the 3D information produced in G-codes. Additionally and/or alternatively, the engraved substrate may be used to receive the printed image or as a base to form a mould to reproduce identical in relief substrates. Each one would receive the printed image. The selection of material for the said substrate will be chosen considering environmental conditions such as indoor/outdoor environment, proximity to a heat source (e.g. fireplace), CA 02614613 2007-12-21 4 1 etc. Closed cell PVC foam board material has physical characteristics, which would meet these conditions. Preferably, the printing equipment would utilize UV (Ultra-Violet) resistant ink and a UV heat source that would rapidly cure the printing ink in order to prevent smudging and running of the ink on the slope area of the engraved substrate. To ensure complete & proper ink coverage, all "slopes" should not exceed 75 degrees. The 3 axis flat bed printer would allow vertical displacement of the printing heads to accept different substrate thickness varying from {fraction 1/2) inch to {fraction I and 3/41 inches. Preferably, the ink is 100% solid. The UV (Ultra-Violet) resistive ink is solvent free; in such is 100% solid. Preferably the registration technique needed to line up the printed image with the engraved substrate should satisfy registration accuracy of less than {fraction 1/1281 inch (0.02mm) over a minimum surface area of 32 square feet (4 meter square). To ensure coarse registration, the image is first printed onto a transparency. The transparency is held in place from one edge then the substrate is slid under it and lined-up with the substrate. To ensure fine registration a clear layer with saturation of less than 10% is printed on the substrate. Measurements are made in both axis (X,Y) to apply registration correction factors. Various objects, features, aspects and advantages of the present invention will become clearer with the following description and accompanying drawings of a preferred embodiment of the invention. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 illustrates a simplified schematic of a first embodiment of the invention, specifically a system for printing the image of a stonewall panel via a 2D printer onto an engraved substrate. Figure 2 illustrates a representation of a system for printing the image of a stonewall panel via a 2D printer onto an engraved substrate. Figure 3 is a flowchart representing the method for creating texture, specifically for stonewall panel. Figure 4 illustrates a typical 3D printed stonewall. Figure 5 illustrates a typical 3D printed door. Figure 6 illustrates a typical 3D emblem. 50 CA 02614613 2007-12-21 1 DESCRIPTION OF THE PREFERRED EMBODIMENT Embodiments of the present invention are directed to printed stonewall and methods for their construction. Figure I shows a system for printing the image of a stonewall via a 2D 5 printer onto an engraved substrate. As shown in figure 1, an optical digital I interprets the 3D information from a photographic image. A texture file 2 is generated based on the photographic image 1. A print file 3 is generated based on the photographic image 1. The texture file 2 is used to generate the G- codes 4 in Type3 format. The print file 3 is used to prepare the file 5 for the printer in raster- scan. The G-codes 4 are sent to the numerically controlled engraving/milling machine (CNC) router 6 to engrave the substrate 8. The file 5 is sent to the high precision, large surface, flatbed printer 7 (the Inca's model, named "Columbia Turbo") to print the photographic image onto the engraved substrate 8 to obtain an image in relief resulting in a three dimensional representation of the original photographic image. The preferred ink consists of 100% solids UV (Ultra-Violet) resistant ink and a UV heat source to rapidly cure the printing ink in order to prevent smudging and running of the ink on the sloped area of the engraved substrate. It is also within the scope of the invention for the ink to be solvent free, composed of 100% solids, such as SericolT"', the type manufactured by Fuji film. As shown in figure 2, the printer head 9 is positioned 2.2 mm ({fraction 1/101 inch) above the highest point 10 of the substrate. The inkjet pattern 11 is set to ensure complete & proper ink coverage all "slopes" not to exceed 75 degrees 12. The maximum engraved thickness 13 is {fraction 1/4) inch for a maximum substrate thickness 14 of {fraction 1 and 3/41 inches. For the purpose of this disclosure, a "substrate" material is defined as a material having a uniform composition throughout its area and depth, presenting one surface with engraved characteristics. Figure 3 illustrates a flowchart representing the methods for creating texture for stonewall. The bitmap generated in Photoshop 15 is imported in Type3. The substrate 16, comprising dimension X1,Y1,Z1 17 and reference points X0,Y0,Z0 18, is set. Generate in Type Art the solid surface 19 from the bitmap 15 using the following settings for stonewall; white = 0 inch, black = -0.250 inch ({fraction -1/4} inch) and "linear lookup table" = "yes". The white generates the highest relief points. The black generates the lowest relief points. Setting the "linear lookup table" to -yes " allows the software to extrapolate all others relief points in a linear way between white and black. In this preferred case, a 50% gray is set to a relief of -0.125 inch ({fraction -1/81 inch). Setting the "linear lookup table" to "no" allows the software to extrapolate all others relief points in a nonlinear way between white and black, whereas the nonlinear relation must be specified. Generate in Cam the G-codes 20. Engrave the relief on the substrate 16 using a ballnose endmill of 0.375 inch ({fraction 3/8) inch) diameter 21 and a stepover de 0.0937 inch. The stopover represents the spacing between each parallel pass. Figure 4, the printed stonewall 22 is vertically self-supporting and can be moved and installed to any wall without the need of a reinforced backing. A"vertically self- supporting substrate" is defined as a substrate with the ability to support its own weight when in a vertical configuration. CA 02614613 2007-12-21 6 The printed stonewall 22 iliustrated in figure 4 consists of a closed cell PVC foam board. It is also within the scope of the invention for the substrate to be composed of this material, for example, the type known as SintraTM, manufactured by Alcan Composites. Such substrate has thermoplastic properties. In this embodiment, the printed stonewall 22 may be approximately four feet wide, eight feet high, and {fraction 1/2} inch deep. However, it is also within the scope of the invention for the area of the sheets to be larger or smaller, depending on the need of the user. Thus, a printed stonewall 22 with a depth of between {fraction 1/2} and {fraction 1/4} inch and an area of four square feet can be used for other application, like an emblem. Preferably, the printed stonewall 22 is a nominal {fraction 3/4} inch deep, is vertically self- supporting and can be engraved with a router. The printed stonewall 22 has an inside surface facing a construction wall, and an outside surface facing away from that wall. A protective layer can be added to the outside surface of a printed stonewall 22 or between two adjacent printed stonewalls to improve its resistance and continuity between the two. Although the invention is presented in terms of a printed stonewall, the embodiments are not intended to limit the scope to a stonewall, whereas the terms "stonewall'" can be replace with the term "door' 23 as show in figure 5 or replace with the term "emblem 24 as show in figure 6. Although the foregoing describes the invention in terms of embodiments, the embodiments are not intended to limit the scope of the claims. Rather, the claims are intended to cover all modifications and alternative printing techniques falling within the spirit and scope of the invention, and are limited only by the plain meaning of the words as used in the claims. 35 45
