Note: Descriptions are shown in the official language in which they were submitted.
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
