Embossed Laminated Substrates With Integer-Ratio Pattern Alignment

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Solution Overview

Problem

Existing methods for producing laminated substrates with embossed structures result in repetitive patterns due to the limited number of unique designs possible with engraving gravure cylinders and embossing rollers, leading to undesirable repetitions when installing flooring panels.

Innovation Solution

A method involving the use of gravure cylinders with circumferences exceeding the perimeter of embossing devices, ensuring the circumference of the gravure cylinder divided by the embossing device corresponds to an integer, allowing for unique patterns on the substrate that can be divided into panels with precise alignment of the embossed structure with the printed pattern.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If gravure cylinders and embossing rollers are used with traditional engraving methods, then the manufacturing process is simple and cost-effective, but the number of unique designs is limited resulting in repetitive patterns

Engineering Contradiction:

Improvenumber of unique designsVSAvoidcomplexity of gravure cylinder and embossing roller

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The gravure cylinder is divided into multiple sections, each engraved with a different pattern design. This segmentation allows a single cylinder to produce multiple unique patterns by rotating to different sections, thereby increasing design variety without requiring multiple separate cylinders or complex reconfiguration systems.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system dynamically switches between different pattern sections on the gravure cylinder during the printing process. By making the pattern selection dynamic rather than static, the system can produce multiple unique designs using the same physical hardware, avoiding the need for complex custom engraving for each design variant.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If the circumference of the gravure cylinder is made to exceed the perimeter of the embossing device by an integer ratio, then the embossed structure aligns precisely with the printed pattern, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvealignment between embossed structure and printed patternVSAvoiddifficulty of achieving precise circumference ratio

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The design deliberately sets the circumference of the gravure cylinder to be an integer multiple of the embossing device perimeter, creating a simple rational relationship between the two components. This parameter choice ensures precise alignment while keeping the manufacturing challenge manageable through standard precision machining capabilities rather than requiring complex tolerances.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If multiple unique patterns are implemented to avoid repetition, then the visual appeal and realism of the panel is improved, but the cost of engraving multiple gravure cylinders and embossing rollers increases

Engineering Contradiction:

Improvevariety of patternsVSAvoidcost of engraving gravure cylinders and embossing rollers

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

A single gravure cylinder is designed to serve multiple functions by incorporating multiple pattern sections. This multi-functional design eliminates the need to engrave and maintain multiple separate cylinders, significantly reducing the cumulative cost of tooling while still providing access to multiple unique patterns through rotational selection.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The gravure cylinder is segmented into multiple pattern sections that can be selectively engaged during printing. This segmentation allows one cylinder to replace multiple dedicated cylinders, reducing the total number of engraving operations required and thereby lowering the overall manufacturing cost while maintaining pattern variety.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12466174B2Method to produce a laminated substrate and such a laminated substrate

Publication Date: 2025.11.11 VÄLINGE INNOVATION AB

AI summary

A method to produce a laminated substrate with an embossed structure, including: providing a polymer based film printed by at least one gravure cylinder, applying the polymer based film on a substrate including a polymer based material, pressing said polymer based film to the substrate, thereby forming a laminated substrate, and embossing the laminated substrate by an embossing device such that the laminated substrate obtains an embossed structure, wherein a circumference of said at least one gravure cylinder exceeds a perimeter of the embossing device, and wherein the circumference of said at least one gravure cylinder divided by the perimeter of the embossing device substantially corresponds to an integer.