Embossed Panel Production With Non-Repeating Roller Patterns
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Solution Overview
Problem
Existing methods for producing panels with embossed structures result in repetitive patterns, limiting the variety of designs and reducing the realistic look and feel of flooring materials like SPC tiles.
Innovation Solution
A method involving a substrate with a polymer-based material, applying a printed polymer-based film, pressing and embossing the laminated substrate with an embossing device having a non-integer perimeter relative to the panel length, and dividing the laminated substrate into panels to achieve unique embossed structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If gravure cylinders and embossing rollers are engraved with patterns, then the panel obtains an embossed structure with decorative print, but the number of unique designs is limited due to engraving costs
Solution Approach 1:
The patent changes the parameter of the embossing device perimeter relative to panel length from an integer ratio to a non-integer ratio (e.g., 1.5:1, 2:1). This parameter change allows a single embossing roller to produce multiple unique embossed patterns across different panels, increasing design variety without requiring multiple engraved rollers. The non-integer ratio ensures that the embossed structure does not repeat at panel boundaries, creating visually distinct panels from a single rolling element.
2Productivity
If the embossing device perimeter corresponds to the panel length, then the production process is simplified, but repetitive patterns occur after a number of panels
Solution Approach 1:
The patent introduces asymmetry in the relationship between embossing device perimeter and panel length by using a non-integer ratio. This asymmetric relationship prevents the embossed pattern from aligning and repeating at regular panel intervals. For example, with a 2:1 ratio, the embossed structure on one panel does not match the embossed structure on adjacent panels, eliminating visual repetition while maintaining continuous production efficiency.
3Productivity
If a single embossing roller is used for continuous production, then productivity is maintained, but the number of non-identical panels is reduced
Solution Approach 1:
The patent utilizes parameter change (non-integer ratio between embossing device perimeter and panel length) to enable a single embossing roller to generate multiple unique panel designs during continuous production. The non-integer ratio ensures that each panel receives a unique portion of the embossed pattern, maximizing variety from a single rolling element while maintaining continuous production throughput.
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 increases the number of non-identical panels by ensuring the embossed structure on each panel is distinct, enhancing the realistic appearance and reducing repetitive patterns.
Implementation Method 1
pressing the printed polymer based film to the substrate, thereby forming a laminated substrate
Implementation Method 2
embossing the laminated substrate by an embossing device having a perimeter, such that the laminated substrate obtains an embossed structure
Data Source
AI summary
A method to produce a panel with an embossed structure, including forming a substrate by a continuous process, wherein the substrate includes a polymer based material, providing a printed polymer based film, applying the printed polymer based film on the substrate, the printed polymer based film being continuously applied on the substrate, pressing the printed polymer based film to the substrate, thereby forming a laminated substrate, and embossing the laminated substrate by an embossing device having a perimeter, such that the laminated substrate obtains an embossed structure, dividing the laminated substrate into panels, each panel having a length and a width, and wherein the perimeter of the embossing device divided by the length of said panel is a non-integer.