Dewatering Screen Plastic Overmoulding for Paper Security Features
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing paper production methods require separate steps for creating security features like sharp-edged holes and watermarks, leading to inefficiencies and register fluctuations between papermaking and additional processing steps like laser cutting or punching.
Innovation Solution
A drainage screen with a carrier screen and an inlay element connected via plastic overmoulding or back-injection, allowing for simultaneous production of multiple security features with precise registration, including sharp-edged holes and watermarks, by integrating diverse materials and shapes that cannot be conventionally combined.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate laser cutting or punching steps are used to create sharp-edged holes in paper, then sharp-edged security features can be produced, but production effort increases and register fluctuations occur between papermaking and additional processing steps
Solution Approach 1:
The patent combines multiple security feature creation functions into a single drainage screen assembly. The carrier screen with watermark relief and the separate insert element for sharp-edged holes are integrated together, allowing simultaneous production of both watermark and sharp-edged holes in one papermaking pass, eliminating the need for separate laser cutting or punching steps and ensuring perfect registration.
2Manufacturing precision
If multiple security features with different visual appearances are produced simultaneously, then registration accuracy improves, but the complexity of integrating different materials and shapes increases
Solution Approach 1:
The drainage screen is segmented into functionally independent components: a carrier screen with watermark relief and a separate insert element for creating sharp-edged holes. This segmentation allows each component to be optimized for its specific function while maintaining ease of manufacture, and the components are then integrated through overmoulding or back-injection to achieve perfect registration.
Solution Approach 2:
The patent uses plastic overmoulding or back-injection as an intermediary connecting mechanism between the carrier screen and the insert element. This intermediary material bonds the different components together while allowing for thermal expansion differences and enabling the integration of diverse materials (metal, plastic, wood) that cannot be conventionally combined.
3Adaptability or versatility
If conventional integration methods are used for different materials in screen fabric, then material compatibility is limited, but the plastic overmoulding or back-injection requires additional manufacturing steps
Solution Approach 1:
The patent utilizes parameter changes in the plastic material during the overmoulding or back-injection process. The plastic starts in a molten state to flow into and bond with the carrier screen and insert element, then cools and solidifies to create a permanent, strong connection. This parameter change allows the plastic to adapt to different materials (metal, plastic, wood) and shapes during integration.
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 efficient production of complex security features in paper with precise registration, eliminating the need for separate work steps and improving the alignment of security elements, enhancing security and visual appeal while reducing production effort.
Implementation Method 1
a plastic overmoulding or plastic back-injection molding of the inlay element, which connects the inlay element to the carrier screen
Implementation Method 2
a plastic overmoulding or plastic back-injection molding of the inlay element, which connects the inlay element to the carrier screen
Data Source
Figure 1~2b
Figure 3~5
Figure 6a~6b
AI summary
The invention relates to a dewatering filter (20) for producing paper with at least one security feature, comprising - a support filter (22) which contains a filter fabric (24) with an insert region (30), - an insert element (32) which is arranged in the insert region (30) of the filter fabric (24) for producing the at least one security feature in the paper, and - a plastic insert molding (34) or a plastic in-molding (36) of the insert element (32), said molding connecting the insert element (32) to the support filter (20).