Embossed Laminated Substrates With Reduced Pattern Repetition
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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 a polymer-based film printed by gravure cylinders, applied to a substrate, and embossed using an embossing device where the circumference of the gravure cylinder is designed to exceed the perimeter of the embossing device, ensuring the embossed structure aligns with unique patterns on the film, allowing for continuous production of varied designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If gravure cylinders and embossing rollers are used to produce patterns, then the manufacturing process is simple and cost-effective, but the number of unique designs is limited causing pattern repetition
Solution Approach 1:
The patent divides the pattern production into two separate functional components: a gravure cylinder that produces the printed pattern and an embossing roller that creates the embossed structure. By segmenting these functions, each component can be optimized independently, allowing the gravure cylinder to handle diverse printed patterns while the embossing roller maintains a simple, reusable structure. This segmentation enables unlimited design variations through the gravure cylinder without increasing embossing roller complexity.
Solution Approach 2:
The patent uses a digital printing process to create the gravure cylinder patterns, allowing unlimited design variations to be copied and reproduced without physical modification of the cylinder itself. This digital copying approach enables infinite design flexibility while keeping the physical gravure cylinder and embossing roller relatively simple and reusable components.
2Manufacturing precision
If the circumference of the gravure cylinder is made larger to exceed the perimeter of the embossing device, then pattern repetition is minimized, but the manufacturing complexity increases
Solution Approach 1:
The patent establishes a specific parameter relationship between the gravure cylinder circumference and embossing device perimeter, where the gravure cylinder circumference is made to exceed the embossing device perimeter by a factor that corresponds to an integer. This parameter change creates a mathematical relationship that ensures precise alignment and registration between the printed pattern and embossed structure, minimizing pattern repetition while maintaining manufacturing feasibility through standardized dimensional relationships.
3Adaptability or versatility
If multiple unique patterns are produced using gravure cylinders, then design variety increases, but the cost for engraving gravure cylinders increases
Solution Approach 1:
The patent creates a universal embossing roller design that can work with multiple different printed patterns generated by the gravure cylinder. The embossing roller serves a universal function of creating embossed structures regardless of the specific printed pattern, allowing the same embossing roller to be used across different design variations. This multi-functionality reduces overall manufacturing costs by avoiding the need to create new embossing rollers for each unique pattern design.
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 enables the production of laminated substrates with unique embossed patterns that minimize pattern repetition, enhancing the realistic look and feel of flooring panels by ensuring precise alignment and registration of embossed structures with printed designs.
Implementation Method 1
providing a polymer based film printed by at least one gravure cylinder
Implementation Method 2
embossing the laminated substrate by an embossing device such that the laminated substrate obtains an embossed structure
Implementation Method 3
pressing said polymer based film to the substrate, thereby forming a laminated substrate
Data Source
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.