Embossing Device Diagonal Film Web Lacquer Wedge
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Solution Overview
Problem
Existing methods for producing security elements with embossed structures in the micrometer or nanometer range on a film web face challenges in achieving uniform lacquer application and consistent embossing, leading to unpredictable properties and increased rejects in security documents.
Innovation Solution
A device is developed with specific configurations of printing and embossing units, where the film web is fed diagonally or vertically into the units, forming a predictable and uniform 'lacquer wedge' on the embossing cylinder, allowing for precise embossing of structures in the micrometer or nanometer range on both sides of the film web without the need for substrate rotation, ensuring consistent properties and reduced rejects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the film web is fed horizontally into the printing and embossing units, then the equipment layout is simplified, but the lacquer layer distribution becomes uneven and unpredictable
Solution Approach 1:
The patent inverts the conventional horizontal feeding approach by feeding the film web vertically or diagonally from above into the printing and embossing units. This inversion creates a predictable 'lacquer wedge' formation where gravity assists in achieving uniform lacquer distribution across the embossing cylinder surface, thereby improving manufacturing precision without significantly increasing device complexity.
2Adaptability or versatility
If substrate rotation is used to apply lacquer and embossing structures on both sides, then both sides can be processed, but registration precision and embossing consistency deteriorate
Solution Approach 1:
The patent segments the processing of front and back sides into separate sequential operations. The film web is fed vertically through the first printing and embossing units for the back side, then continues through the second printing and embossing units for the front side. This segmentation eliminates the need for substrate rotation, maintaining precise registration and embossing consistency while still enabling both sides to be processed.
3Device complexity
If the film web enters the embossing unit from below, then the equipment configuration is simplified, but the lacquer wedge formation becomes unpredictable
Solution Approach 1:
The patent inverts the conventional bottom-fed configuration by feeding the film web from above into the embossing unit. This inversion allows gravity to work in favor of uniform lacquer distribution, creating a predictable 'lacquer wedge' that ensures consistent embossing quality. The equipment configuration remains relatively simple while achieving superior manufacturing precision.
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 results in a predictable and uniform lacquer layer with consistent embossed structures, reducing defects and enhancing the counterfeiting protection of value documents by maintaining smooth film web guidance and precise registration of embossing patterns, thereby improving the quality and reliability of security features.
Implementation Method 1
a first printing unit for applying a first coat of paint, which can be cured by means of ultraviolet radiation, to the back of the film web
Implementation Method 2
In the respective two embossing units, the foil web is first pressed in the direction of transport with the side on which the not yet hardened lacquer layer is located by a pressure roller against an embossing cylinder
Data Source
Figure 1A~1
Figure 2~3
AI summary
The invention relates to a device for producing security elements, wherein the security elements are arranged on a front side and a rear side of a film web, and are formed by embossed structures in a coating layer with dimensions in the region of micro- or nanometers. According to the invention, in the conveying direction of the film web, the device has the following equipment: a device for providing a film web; a first printing mechanism for applying a first coating layer that can be cured via ultraviolet light to the rear side of the film web; a first embossing mechanism for embossing first structures with dimensions in the region of micro- or nanometers in the first coating layer; a second printing mechanism for applying a second coating layer that can be cured via ultraviolet light to the front side of the film web; and a second embossing mechanism for embossing second structures with dimensions in the region of micro- or nanometers in the second coating layer. According to the invention, the film web travels into the first printing mechanism from below or transversely from below, into the first embossing mechanism from above or transversely from above, into the second printing mechanism also from above or transversely from above, and in turn into the second embossing mechanism from below or transversely from below. Alternatively, the film web travels into the first printing mechanism from above or transversely from above, into the first embossing mechanism from below or transversely from below, into the second printing mechanism also from below or transversely from below, and in turn into the second embossing mechanism from above or transversely from above.