Cylinder Structured Surface UV-Curable Lacquer Transfer
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Solution Overview
Problem
Current methods for producing microstructured or nanostructured surfaces on large areas, such as glass facades and solar technology, are not economically viable due to challenges in creating seamless embossing tools with high-quality surface structures in the micro or nano range, particularly for cylindrical surfaces.
Innovation Solution
A method involving the transfer of a thin UV-curable lacquer layer with a surface structure from a template to a cylindrical surface, using a rolling process with precise UV exposure to achieve a seamless, high-quality structured surface, which can then be used to create an embossing tool for replicating the structure on other materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional lithography methods are used to produce microstructured surfaces, then high manufacturing precision can be achieved, but the productivity is low and the process is not economical for industrial-scale production on large areas
Solution Approach 1:
The invention segments the structured surface into discrete elements (protrusions and recesses) that can be independently formed through embossing. The cylindrical surface is divided into multiple sectors, each containing the complete pattern, allowing parallel production across the entire surface area, thus increasing productivity while maintaining precision
Solution Approach 2:
The invention creates a master pattern that is copied repeatedly across the cylindrical surface through embossing. The structured pattern is transferred from a template to the coating layer, which is then wrapped around the cylinder, enabling high-speed replication of the microstructure over large areas without sacrificing precision
2Manufacturing precision
If diamond cutting or laser direct structuring is used to create seamless embossing rollers, then manufacturing precision can be achieved, but the smallest achievable structure widths are above 10 micrometers
Solution Approach 1:
The invention introduces a coating layer as an intermediary medium between the embossing tool and the final product. This coating layer can be applied in a thin, uniform manner that captures fine structural details, enabling the formation of structures with widths below 10 micrometers while maintaining high manufacturing precision through the embossing process
Solution Approach 2:
The invention changes the physical parameters of the embossing process by using a coating layer that can be cured or set after embossing. This allows for the formation of extremely fine structures (below 10 micrometers) that would be difficult to achieve with traditional mechanical methods, as the coating material can be deposited and formed at controlled thicknesses and then stabilized
3Productivity
If a flat embossing die is mounted onto a hollow cylinder to create a continuous structure, then productivity can be improved, but clearly perceptible seams appear at the points where the surface structure repeats
Solution Approach 1:
The invention adapts the embossing tool to a cylindrical geometry that matches the substrate. By using a cylindrical embossing tool with the pattern distributed around its circumference, the structure can be formed continuously around the cylinder without creating perceptible seams, as the transition points are obscured by the curvature and pattern repetition
Solution Approach 2:
The invention varies the local properties of the embossed pattern by positioning different portions of the pattern around the cylindrical embossing tool. The pattern is designed so that the transition zones between repeated elements are minimized or hidden, creating a seamless appearance while maintaining continuous production capability
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
Enables the production of cylinders with structured surfaces having features as small as 50 nm, with imperceptible seams, allowing for high-quality embossing tools that can efficiently replicate micro- or nanostructures on large areas without visible seams, suitable for industrial applications.
Implementation Method 1
A layer of UV-curable lacquer with a structural field is transferred from the template surface to the outer surface of the cylinder as the cylinder rolls relative to the template surface
Data Source
Figure 1~2
Figure 3~6
Figure 7a~7e
AI summary
Disclosed are a method and a device for producing a cylinder (16) having a structured surface, as well as an embossing tool produced therefrom and a embossed product produced with the embossing tool. A structural field is formed as a paint layer (20) with a thickness of 800 nm or less on a support surface (14) having a surface structure, said structural field moulding the surface structure. The structural field (20) is applied onto the outer surface of a cylinder (16). In this way, a largely seamlessly appearing surface structure can be achieved on the cylinder (16).