3D Pattern Metal Card Layering to Prevent Peeling and Debris

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Solution Overview

Problem

Metal cards face issues such as peeling of 3D patterns, generation of metal debris, and deterioration of metallic feel due to UV pattern printing, along with sheet matching inaccuracies, which hinder efficient production and aesthetics.

Innovation Solution

A manufacturing method involving an adhesive layer on a metal body with specific surface roughness, followed by vacuum deposition and double UV pattern printing with a digital printing layer in between to minimize peeling and debris, while maintaining metallic feel.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If UV pattern printing is performed directly on a metal body to form a 3D pattern, then the 3D pattern can be formed, but peeling between the metal body and the 3D pattern print layer occurs easily due to fine differences and unique surface smoothness of metal material

Engineering Contradiction:

Improve3D pattern formationVSAvoidadhesiveness of 3D pattern

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

An adhesive layer is introduced as an intermediary between the metal body and the UV pattern printing layer. This adhesive layer serves as a mediator that bonds the 3D pattern to the metal substrate, preventing peeling while maintaining the 3D effect. The adhesive layer compensates for the fine surface differences and smoothness of the metal material.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates a composite structure consisting of multiple layers: the metal body, the adhesive layer, and the UV pattern printing layer. This composite material approach combines the advantages of each layer - the structural integrity of metal, the bonding capability of adhesive, and the 3D pattern formation capability of UV printing.

Inventive Principle:

Principle #40Composite materials

2Shape

If UV pattern printing is performed on metal body, then 3D pattern can be formed, but a lot of metal debris is generated in the process and it is difficult to treat the debris

Engineering Contradiction:

Improve3D pattern formationVSAvoidmetal debris generation

Core Design Contradiction:

ShapeVSObject-generated harmful factors

Solution Approach 1:

The adhesive layer acts as a protective intermediary that prevents direct contact between the UV printing process and the metal body, thereby reducing metal debris generation. The adhesive layer absorbs the impact of the printing process without transferring harmful effects to the metal substrate.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Shape

If UV pattern printing is performed on metal body, then 3D pattern can be formed, but the overall metal feeling deteriorates due to the occurrence of warpage caused by the UV 3D pattern printing

Engineering Contradiction:

Improve3D pattern formationVSAvoidmetal feeling and surface integrity

Core Design Contradiction:

ShapeVSStability of the object's composition

Solution Approach 1:

The adhesive layer serves as a buffer intermediary that isolates the metal body from the thermal and mechanical stresses of UV printing. This prevents direct transmission of warpage and surface deformation to the metal substrate, preserving the metal feeling and surface integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Shape

If UV pattern printing is performed on metal body, then 3D pattern can be formed, but inaccuracy of sheet matching occurs due to the UV pattern printing

Engineering Contradiction:

Improve3D pattern formationVSAvoidsheet matching accuracy

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The adhesive layer acts as a stable intermediary that provides a consistent bonding surface, reducing variations in sheet matching. By isolating the printing process from the metal body, it maintains dimensional stability and improves matching precision across multiple sheets.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 method enhances adhesiveness, minimizes peeling and debris, and maintains metallic appearance, enabling high-efficiency production of 3D pattern metal cards with improved aesthetics at lower costs.

Implementation Method 1

forming an adhesive layer on a body plate made of a metal material

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

performing a vacuum deposition process using a first metal base on the adhesive layer

Methodology Applied

Scientific EffectVacuum deposition: Physical Vapour Deposition

Implementation Method 3

print-processing a 3D pattern layer by using UV on a surface of the adhesive layer

Methodology Applied

Scientific EffectUV curing: Photopolymerisation

Data Source

PatentUS12479229B2Card with 3D pattern and manufacturing method thereof

Publication Date: 2025.11.25 KONAM

AI summary

According to an embodiment of the present disclosure, a method of manufacturing a card by using a card manufacturing device includes the steps of: forming an adhesive layer on a body plate made of a metal material having a preset first surface roughness; performing a vacuum deposition process using a first metal base on the adhesive layer; and print-processing a 3D pattern layer by using UV on a surface of the adhesive layer on which the vacuum deposition process was performed.