Cosmetic Sheet Embossing via Single Roll and Rubber Back
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Solution Overview
Problem
Existing methods for manufacturing cosmetic sheets with high cellulose fiber content are expensive and inefficient, particularly when attempting to create uneven surfaces without using a male-female embossing unit.
Innovation Solution
A method involving the lamination of thermoplastic resin between base papers with 50% or more cellulose fiber, followed by an embossing process using a specific embossing roll and rubber back roll configuration to create a good uneven shape, allowing for cost-effective production of cosmetic sheets and panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a male-female embossing unit is used to create uneven surfaces on high cellulose fiber cosmetic sheets, then the uneven surface quality is improved, but the manufacturing cost and device complexity increase
Solution Approach 1:
The invention extracts and removes the complex male-female embossing unit from the system, replacing it with a simple single embossing roll that has unevenness formed on its surface. This unevenness is created by pressing a cosmetic sheet against the embossing roll during the printing process, eliminating the need for a separate embossing unit while achieving the desired uneven surface effect.
Solution Approach 2:
The invention merges the embossing function with the existing printing process by integrating the embossing roll into the printing mechanism. The uneven surface is formed simultaneously during printing by pressing the cosmetic sheet against the embossing roll, combining two functions (printing and embossing) into one operational step without requiring separate equipment.
2Ease of manufacture
If thermoplastic resin is inserted into base paper to enable embossing, then the embossing capability is improved, but the material cost and special specifications required increase
Solution Approach 1:
The invention uses inexpensive, readily available base paper with high cellulose fiber content (50% or more) without requiring special modifications or insertion of thermoplastic resin. The base paper is used in its natural state, and the embossing capability is achieved through the mechanical pressing process during printing, eliminating the need for costly material modifications.
3Productivity
If coated paper is used for cosmetic sheets, then the productivity and cost are improved, but the ability to apply unevenness to the surface deteriorates
Solution Approach 1:
The invention changes the key parameter of base paper from requiring thermoplastic resin insertion to using high cellulose fiber content (50% or more) with specific thickness (15-60 μm). This parameter change enables the paper to be directly embossed during printing without requiring complex male-female embossing units, thereby maintaining high productivity while achieving good uneven surface effects.
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 enables the production of cosmetic sheets and panels with enhanced designability and uneven surface texture at a lower cost, without the need for a male-female embossing unit, while maintaining the strength and durability of high cellulose fiber content.
Implementation Method 1
a laminating step for forming a laminate by arranging a thermoplastic resin layer having a melting point of no less than 100°C and no greater than 200°C and having a thickness of no less than 20 μm and no greater than 70 μm between the pair of base papers, and adhering together the pair of base papers using the thermoplastic resin layer
Implementation Method 2
a laminating step for forming a laminate by arranging a thermoplastic resin layer having a melting point of no less than 100°C and no greater than 200°C
Implementation Method 3
a processing step of applying an embossed shape to the laminate by passing the laminate between an embossing roll having a maximum depth of 15 μm or greater and a rubber back roll having a hardness of 50° or greater but less than 95° that is measured based on ISO 7619
Data Source
AI summary
A method for manufacturing a cosmetic sheet, the method including a preparation step for preparing a pair of base papers containing 50% by mass or more of cellulose fiber, and having a thickness of no less than 15 μm but less than 60 μm; a laminating step for arranging a thermoplastic resin layer having a melting point of 100° C. to 200° C. and thickness of 20 to 70 μm between the pair of base papers, and adhering together the base papers using the thermoplastic resin layer to form a laminate; and a processing step for passing the laminate between an embossing roll having a maximum depth of 15 μm or greater, and a rubber back roll having a hardness of no less than 50° but no greater than 95° that is measured on the basis of ISO 7619, and applying an embossed shape to the laminate.