Eccentric Drive Embossing for Packaging Lids
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Solution Overview
Problem
Existing methods for producing partially embossed and printed sealable packaging lids and labels face challenges such as embossing affecting print quality, difficulty in reading small text, and time-consuming roller replacements, which hinder efficient stacking and format changes.
Innovation Solution
The method involves using an eccentric drive to shift embossing plates relative to the film strip, allowing for non-congruent embossing patterns and easy tool exchange, ensuring embossings do not coincide between lids, and coordinating embossing with printing using existing print marks, enabling efficient production of both flat and deep-drawn lids and labels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surface embossing is applied to promote stacking, then stacking is improved, but print brilliance is lost and small print becomes difficult to read
Solution Approach 1:
The patent applies embossing only to specific contact areas at the periphery of the lid where stacking contact occurs, while leaving the central printed area smooth and unembossed. This localized embossing approach ensures reliable stacking at the contact zones without compromising the brilliance and legibility of the printed information in the center.
2Reliability
If embossing rollers are used for partial embossing, then stacking is improved, but roller replacement becomes time-consuming and expensive
Solution Approach 1:
The embossing function is divided into multiple stationary embossing plates arranged in series, with each plate applying embossing to a different section of the lid. This segmentation allows the system to maintain embossing capability without requiring replacement of individual rollers, as the plates remain stationary and can be independently adjusted or replaced as needed.
Solution Approach 2:
The patent employs an eccentric drive mechanism that dynamically adjusts the positioning of embossing plates relative to the moving film strip. This dynamic positioning system allows for easy reconfiguration when changing products by simply adjusting the plate positions rather than replacing entire rollers, significantly reducing downtime.
3Reliability
If embossing patterns are made non-congruent between lids, then stacking safety is improved, but coordination between embossing and printing becomes more difficult
Solution Approach 1:
The patent uses reading marks or alignment features that are preliminarily applied to the film strip before the embossing process. These marks serve as reference points that allow the embossing plates to be precisely positioned and coordinated with the printing process, ensuring non-congruent embossing patterns while maintaining easy coordination between the two operations.
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 ensures brilliant print retention, easy format changes, and reduced downtime by allowing for quick roller exchanges, ensuring safe stacking and maintaining print legibility while minimizing corrections due to film stretching.
Implementation Method 1
With an eccentric drive, which shifts the embossing plates from cycle to cycle in relation to the film strip, the necessary uneven coverage can be reliably achieved in a simple manner.
Implementation Method 2
the embossing tool 23 comprises two embossing plates 25 and 27. The upper embossing plate 27 can be pressed in direction Y onto the lower embossing plate 25
Implementation Method 3
the foil strip 3 passes between an embossing tool 23 either directly or via a second deflection roller 21. From there, the film strip 3 passes between an embossing tool 23
Data Source
Figure 1
Figure 2
AI summary
The embossing (39) on a printed foil strip (3) is carried out by an embossing tool (23), which embossing tool (23) is adjustable relative to the foil web by an eccentric drive (35). The embossing tool (23) performs the embossing synchronously with each or every second punching cycle of the punching tool (47) while the foil strip (3) is stationary.