Asymmetric Embossing Roll Sidewall Angles for Precision
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Solution Overview
Problem
Conventional embossing processes face limitations in achieving precise pattern definition due to restricted sidewall angles and spacing between embossing elements, leading to suboptimal embossing quality and short service life of laser-engraved rolls.
Innovation Solution
Employing embossing elements with non-symmetric sidewall angles, where one sidewall has a steep angle and the other has a negative or smaller angle, to enhance pattern definition, and using laser engraving or Electric Discharge Machining to produce embossing rolls with improved durability and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional embossing elements with symmetric sidewall angles are used, then the manufacturing process is simple, but the embossing definition and pattern precision are limited
Solution Approach 1:
The patent applies asymmetry by designing embossing elements with non-symmetric sidewall angles, where one sidewall has a different angle than the other. This asymmetric geometry creates superior pattern definition and embossing precision in the substrate, directly resolving the contradiction between manufacturing precision and device complexity by accepting increased geometric complexity to achieve significantly improved embossing quality
2Productivity
If laser engraving is used to create embossing rolls, then production speed is improved, but the service life of the rolls is short
Solution Approach 1:
The patent applies parameter changes by modifying the sidewall angle parameters of embossing elements to optimize both the engraving process and the resulting roll durability. By carefully selecting and controlling the geometric parameters during laser engraving, the patent achieves both high production speed and extended roll service life, resolving the contradiction between productivity and duration of action
3Manufacturing precision
If steep sidewall angles are used in embossing elements, then pattern definition is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent applies mechanics substitution by replacing traditional mechanical engraving methods with laser engraving technology. This substitution enables the creation of steep sidewall angles and complex asymmetric geometries that would be difficult or impossible to achieve with conventional mechanical tools, thereby achieving superior pattern definition while maintaining manufacturing feasibility through advanced laser processing techniques
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 approach allows for superior embossing definition and longer roll life, enabling more precise and visually appealing embossed substrates with improved tactile properties and user perception.
Implementation Method 1
An engraved roll suited to commercial production having a long life and providing superior embossing definition can be manufactured for example by laser engraving these elements onto a conventional steel roll
Implementation Method 2
Suitable rolls may also be produced by using Electric Discharge Machining or Electric Deposition of Materials processes in place of the laser engraving process
Implementation Method 3
Suitable rolls may also be produced by using Electric Discharge Machining or Electric Deposition of Materials processes in place of the laser engraving process
Data Source
AI summary
An apparatus including a surface containing at least one embossing element. The embossing element having a first sidewall angle and a second sidewall angle and wherein the first sidewall angle is different than the second sidewall angle.