Dewatering Screen Watermark Inserts for High-Resolution Paper
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Solution Overview
Problem
Current methods for producing high-resolution watermarks in paper, such as those used in security documents, are labor-intensive and costly, as they require custom electrotypes or injection molds for each watermark design, limiting flexibility and increasing production expenses.
Innovation Solution
A drainage wire with individualized watermark inserts that feature a series watermark area identical across all copies and an individualized watermark area unique to each copy, where the individual area is created using laser engraving or shaped elements, allowing for customizable and cost-effective production of high-resolution, multi-level watermarks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom electrotypes or injection molds are used for each watermark design, then high-resolution watermark quality is achieved, but production cost and complexity increase significantly
Solution Approach 1:
The watermark insert is divided into two functional areas: a series watermark area with high-resolution multi-level relief structure and an individual watermark area with binary structure. This segmentation allows each area to be optimized independently - the series area provides high resolution while the individual area provides simple, cost-effective customization.
Solution Approach 2:
A single watermark insert design serves multiple functions: it contains both the standardized series watermark (identical across all copies) and the variable individual watermark (unique to each copy). This universal design eliminates the need for separate electrotypes or molds for each complete watermark configuration.
2Adaptability or versatility
If manual soldering of electrotypes is used for individual watermarks, then customization is achieved, but labor time and production cost increase
Solution Approach 1:
The manual mechanical process of soldering electrotypes is replaced with an automated injection molding process. The individual watermark area is formed directly during injection molding using a correspondingly structured mold, eliminating the need for manual soldering operations while maintaining customization capability.
Solution Approach 2:
The individual watermark structure is prepared in advance within the injection mold cavity. During the injection molding process, the plastic material is formed directly into the desired individual watermark pattern, so no subsequent assembly or modification is needed. This preliminary action within the mold eliminates time-consuming post-processing steps.
3Adaptability or versatility
If different injection molds are milled for different watermarks, then watermark variety is achieved, but manufacturing cost increases
Solution Approach 1:
The injection mold is designed with differentiated local structures: the series watermark area uses a high-resolution multi-level relief structure for consistent quality, while the individual watermark area uses a simpler binary structure (flat surface sections at two height levels). This local quality differentiation allows the individual area to be easily reconfigured for different watermarks without requiring expensive high-resolution mold work.
Solution Approach 2:
The individual watermark area utilizes a binary structure with only two height levels, representing a parameter simplification compared to the multi-level series area. This parameter change (from multi-level to binary) reduces the complexity and cost of mold manufacturing while still achieving effective watermark functionality through contrast creation.
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 visually attractive, customizable watermarks with high contrast and differentiated brightness variations, enhancing authenticity and reducing production time and costs, while allowing for flexible design and positioning of individualized information.
Implementation Method 1
The invention also relates to an injection molding tool for producing high-resolution multi-stage watermark inserts for such dewatering screens
Implementation Method 2
the individual area is created using laser engraving
Data Source
Figure 1~2
Figure 3(a)~4
Figure 5(a)~5(e)
AI summary
The invention relates to a dewatering screen (10) for the production of paper with high-resolution watermarks, comprising a carrier screen (12) with a plurality of individual application areas (14) which, during paper production, each produce a plurality of individual applications of the watermarked paper, wherein the dewatering screen (10) with its individual application areas (14) is provided with watermark inserts (20) which, at least in partial areas (22), are designed as high-resolution multi-stage watermark inserts. According to the invention, it is provided that the watermark inserts (20) each have a serial watermark area (22) that is identical for all individual applications (14) and an individual watermark area (24) that is individualized for each individual application (14).The invention also relates to an injection molding tool (70) for producing high-resolution multi-stage watermark inserts (20) for such drainage screens (10), as well as methods for producing drainage screens of the aforementioned type.