Embossing Media Using On-Demand Die Cutting

Solution Overview

Problem

Existing embossing devices are unsuitable for small quantities of media due to the time and cost associated with creating dedicated dies for embossing shapes.

Innovation Solution

A printing system that integrates a cutter apparatus to produce dies from multi-layer substrates on an ad-hoc basis, allowing for efficient and cost-effective embossing of media, with a controller to control the cutting and embossing processes, and a collector to manage and reuse dies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a dedicated die is created for embossing shapes, then embossing quality is improved, but time and cost increase significantly

Engineering Contradiction:

Improveembossing qualityVSAvoidtime for creating die

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent uses a multi-layer substrate that includes a reusable carrier sheet with pre-formed embossing shapes. Instead of creating a dedicated die for each embossing pattern, the system copies the desired embossing shapes by cutting them from the carrier sheet and transferring them to the media. This allows rapid production of embossing shapes without time-consuming die creation.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The embossing system is segmented into separate functional components: a carrier sheet containing multiple embossing shapes, a cutting apparatus that selectively removes portions of the carrier sheet, and an embossing apparatus that transfers the shapes to media. This segmentation allows independent optimization of each component and enables flexible reconfiguration without recreating the entire embossing system.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If a dedicated die is created for embossing shapes, then embossing quality is improved, but cost increases significantly

Engineering Contradiction:

Improveembossing qualityVSAvoidcost of creating die

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent uses a multi-layer substrate that includes a reusable carrier sheet with pre-formed embossing shapes. Instead of creating a dedicated die for each embossing pattern, the system copies the desired embossing shapes by cutting them from the carrier sheet and transferring them to the media. This allows rapid production of embossing shapes without time-consuming die creation.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The carrier sheet is designed to be reused multiple times. After embossing shapes are cut from the carrier sheet, the remaining portions are retained and can be used to create additional embossing shapes. This recovering and reuse mechanism significantly reduces material waste and production costs compared to creating entirely new dies for each embossing pattern.

Inventive Principle:

Principle #34Discarding and recovering

3Adaptability or versatility

If traditional embossing devices are used, then embossing capability is provided, but adaptability for small quantities is poor

Engineering Contradiction:

Improvesuitability for small quantitiesVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The embossing system is designed to be dynamic and reconfigurable. The carrier sheet can be loaded with different embossing shapes as needed, and the cutting apparatus can be adjusted to create various shapes and patterns. This dynamic reconfiguration capability allows the system to adapt to different embossing requirements without requiring complex dedicated dies for each scenario.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The carrier sheet serves multiple functions: it stores multiple embossing shapes, enables rapid reconfiguration for different embossing patterns, and can be reused across multiple embossing cycles. This multi-functionality provides high adaptability for small quantity embossing while maintaining relatively simple system architecture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9038534B2Embossing media

Publication Date: 2015.05.26 HEWLETT PACKARD INDIGO BV

AI summary

Apparatus for embossing media, the apparatus including cutter apparatus to cut a shape in a surface layer of a multi-layer substrate to form a die. The apparatus also includes an embosser to emboss the media using the die. The cutter apparatus is arranged to provide the die to the embosser.