Digital Embossing Die via Ink Layer Deposition
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional embossing processes require dedicated machinery and are costly, time-consuming, and labor-intensive due to the need for custom-made dies and separate post-printing processes, which delays the integration of embossing into the normal printing flow.
Innovation Solution
The use of a digital Liquid Electro Photographic (LEP) printing system to create embossing dies as printed relief patterns made of multiple ink layers, which can be integrated into the standard printing process, allowing for the embossing of media without the need for additional machinery and reducing overheads by using the same printer for die creation and image printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional dedicated embossing machinery with custom-made dies is used, then embossing quality and precision are improved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent uses digital printing to create copies of embossing dies from digital designs, eliminating the need for traditional custom-made physical dies. The printed relief patterns serve as functional copies that can be rapidly produced and modified, maintaining embossing quality while dramatically reducing manufacturing time and cost.
Solution Approach 2:
The patent changes the material parameters from traditional die materials to printed ink layers, and changes the manufacturing process parameters from mechanical die-making to digital printing. This allows rapid iteration and modification of embossing patterns while maintaining sufficient relief height for quality embossing.
2Manufacturing precision
If traditional separate post-printing embossing process is used, then embossing precision is improved, but process complexity and labor intensity increase
Solution Approach 1:
The patent merges the printing and embossing processes into a single integrated operation. The same digital printer that produces the printed media also creates the embossing die and applies the embossing in one pass, eliminating the need for separate post-printing embossing machinery and reducing process complexity.
Solution Approach 2:
The patent makes the printer universal by enabling it to perform multiple functions: printing the media, creating the embossing die, and applying the embossing all in one device. This multi-functionality eliminates the need for dedicated embossing machinery and simplifies the overall process.
3Adaptability or versatility
If multiple layers of deposited material are used to create embossing die, then embossing versatility is improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the material from traditional multi-layer deposited materials to standard printing inks, achieving the same versatility through digital printing's ability to precisely control material deposition. This reduces material cost while maintaining the ability to create complex multi-level embossing patterns.
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 minimizes delays, handling, and costs associated with traditional embossing systems by integrating the embossing process into the normal printing flow, enabling rapid creation and reuse of embossing dies, and allowing for the embossing of large quantities of media with high-quality results.
Implementation Method 1
a first ink layer image for forming a first layer of an embossing die is developed, transferred and deposited on a substrate... Further ink layer images are subsequently developed, transferred and deposited on the substrate
Data Source
AI summary
An embossing die is created by printing multiple ink layers (530, 540) in superposition thereby to build up a printed relief pattern (510) in accordance with received design data specifying a design to be embossed. The design data is modified after receipt to introduce into the printed relief pattern to be built, one or more channels (610) which extend depth-wise through multiple ink layers of the printed relief pattern (510) and serve to fully or partially segment the printed relief pattern.