Embossed Laminate Alignment Using Printed Image Identifiers
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Solution Overview
Problem
The challenge of matching digitally printed images with embossed in register (EIR) layers on substrates is hindered by material contraction, leading to curling and reduced image clarity, and alignment errors are common due to the difficulty in spatially matching these layers.
Innovation Solution
A laminated article is designed with a printed image and an EIR layer where the printed image includes identifiers to align with the EIR layer's pattern, using optical capture devices or non-optically capturable identifiers to ensure precise alignment, and applying adhesives like PUR adhesive to secure the layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a substantial quantity of liquid material is deposited onto the substrate to form the EIR layer, then the EIR layer can be formed with sufficient material, but material contraction occurs causing the board to curl and reducing image clarity
Solution Approach 1:
The patent applies preliminary drying actions to remove excess liquid material before the EIR layer is fully formed. This prevents material contraction during the curing process, eliminating curling and maintaining image clarity while still allowing sufficient liquid material to be deposited for proper EIR layer formation.
2Measurement precision
If digital printing is used to create the printed image, then image detail and color accuracy are improved, but matching the EIR layer with the printed image becomes difficult and prone to error
Solution Approach 1:
The patent incorporates feedback mechanisms where the printed image serves as a reference pattern that guides the EIR layer formation process. The system continuously monitors and adjusts the EIR layer deposition to maintain precise alignment with the printed image, ensuring that high-resolution printing benefits are preserved without alignment errors.
3Area of stationary object
If more liquid material is used to ensure complete coverage of the EIR layer, then coverage is improved, but material contraction increases causing curling
Solution Approach 1:
The patent applies preliminary drying actions to remove excess liquid material before the EIR layer is fully formed. This prevents material contraction during the curing process, eliminating curling and maintaining image clarity while still allowing sufficient liquid material to be deposited for proper EIR layer formation.
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
The solution achieves precise alignment and secure bonding of printed images with EIR layers, enhancing image clarity and preventing curling, thereby improving the aesthetic quality and structural integrity of the laminated articles.
Implementation Method 1
applying adhesives like PUR adhesive to secure the layers
Data Source
AI summary
An article having a printed image and an embossed in register (EIR) layer is disclosed, the article having a longitudinal axis and a transverse axis that is perpendicular to the longitudinal axis. The article comprises a substrate having a first side. The printed image is positioned on the first side of the substrate. The printed image comprises at least one identifier. The printed image is positioned between the EIR layer and the substrate. The printed image has a pattern, and the EIR layer has a corresponding pattern that is aligned with the pattern of the printed image along the longitudinal axis and the transverse axis.