Embossed Container Lids Simultaneous Gravure Printing
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Solution Overview
Problem
Existing methods for producing printed and embossed cover plates face challenges such as sticking issues during separation, distortion of printed images, and high costs associated with embossing rollers, leading to malfunctions in capping machines and suboptimal optical qualities.
Innovation Solution
A method integrating gravure or flexographic printing processes using forme cylinders with engraved printing elements for both ink transfer and embossing, allowing for simultaneous and precise application of printing inks, sealing wax, and embossing in the same printing machine, without color application for embossing, to ensure alignment and optical advantages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If embossing is performed in a separate pass through an embossing device, then the cover material can be embossed, but the printed image is distorted and any gloss disappears
Solution Approach 1:
The patent combines the printing process and embossing process into a single integrated operation using a printing press with embossing capability. The printing forme serves dual purposes: transferring ink and creating embossing through pressure application during the same pass, eliminating the need for a separate embossing device and preventing print distortion.
Solution Approach 2:
The printing process is performed first, and the embossing is applied simultaneously during the same operation rather than as a subsequent separate step. This preliminary integration ensures that the printed image and embossing are applied in perfect registration without distortion.
2Shape
If embossing rollers are procured and provided, then embossing can be performed, but the cost becomes extremely expensive
Solution Approach 1:
The printing press is designed to perform multiple functions: printing and embossing in the same operation. The printing forme serves dual purposes of ink transfer and embossing creation, eliminating the need for dedicated expensive embossing rollers and reducing overall production costs.
Solution Approach 2:
The patent merges the embossing function into the existing printing press infrastructure, avoiding the need to procure separate expensive embossing equipment. The integrated system uses the printing press's existing mechanisms to accomplish both printing and embossing tasks.
3Ease of manufacture
If cover materials are provided without embossing, then production costs are reduced, but the cover boards stick to one another due to the glass plate effect and cannot be reliably separated
Solution Approach 1:
The patent integrates embossing into the printing process, providing the necessary separation features through the printing press without requiring separate expensive embossing equipment. This maintains production cost efficiency while ensuring reliable cover board separation through the embossed 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
Enables easily separable cover plates with improved optical qualities and reduced production costs by allowing for in-register application of printing inks, sealing wax, and embossing without distortion, using the same printing machine and forme cylinders.
Implementation Method 1
In gravure printing or copper gravure printing using gravure printing machines, the print motif is engraved on a forme cylinder. The indentations of the engraving absorb the color from a paint tray. The excess paint is wiped off with a squeegee. A printing cylinder or impression roller presses the printing material against the forme cylinder, which then applies the ink to the material to be printed.
Implementation Method 2
The printing form for the embossing is in particular a form cylinder with engraved printing elements. In the printing press, the forme cylinders of the printing unit or units that apply the embossing to the printing material... can have the same circumference or diameter as the printing forms in the ink-carrying printing units
Implementation Method 3
A printing cylinder or impression roller presses the printing material against the forme cylinder, which then applies the ink to the material to be printed. A surface pressure is created between the forme cylinder and the impression cylinder.
Implementation Method 4
The excess paint is wiped off with a squeegee.
Data Source
AI summary
The method involves printing a stock printed in a printing press by ink-conducting printing group. The stock is embossed in the printing press or another printing press located behind the former press, and printing components of the printing form are applied to the stock as an embossed pattern. The stock is guided between a form cylinder and an impression cylinder in the printing groups, where the form cylinder is provided with recessed, and/or raised printing components. Blank lids are punched out from the stock. An independent claim is also included for a blank lid containing a printing motive.