Transparent Embossing Roller Light Guide for UV Curing
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Solution Overview
Problem
Prior art embossing systems face challenges with reduced dimensional accuracy and increased maintenance costs due to the thermally unfavorable positioning of UV stations and the need for materials with optical transparency and inherent stability, leading to distortions and higher maintenance efforts.
Innovation Solution
A method and device where crosslinking radiation is coupled into a transparent embossing roller, acting as a light guide, and decoupled for curing the embossing mass, utilizing frustrated total reflection and intrinsic confinement to maintain radiation within the roller, ensuring homogeneous illumination and reduced thermal and mechanical limitations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If UV station is positioned thermally unfavorably next to the embossing roller, then curing can be performed, but dimensional accuracy deteriorates due to thermal distortion
Solution Approach 1:
The UV radiation source is extracted from its traditional position next to the embossing roller and integrated into the embossing roller itself. This allows the radiation source to be thermally isolated from the embossing roller while maintaining close proximity for effective curing, thereby eliminating thermal distortion caused by external UV stations.
Solution Approach 2:
The embossing roller acts as an intermediary between the UV radiation source and the embossing mass. The roller's transparent material allows UV radiation to pass through while providing mechanical support and thermal isolation, enabling the radiation source to be positioned inside the roller without directly heating it.
2Manufacturing precision
If radiation source is integrated into the embossing roller, then dimensional accuracy improves, but maintenance effort increases
Solution Approach 1:
The embossing roller is segmented into functionally independent components: the radiation source module, the transparent roller body, and the embossing surface. This modular design allows the radiation source to be replaced or maintained independently without removing or damaging the embossing roller, thereby reducing maintenance effort.
Solution Approach 2:
The radiation source is designed as a replaceable component that can be quickly exchanged when depleted or malfunctioning. The transparent embossing roller body and embossing surface are recovered and retained, eliminating the need to discard the entire roller assembly and reducing maintenance costs.
3Productivity
If embossing roller material provides optical transparency for UV radiation, then curing efficiency improves, but material selection is restricted
Solution Approach 1:
The embossing roller is constructed as a composite material system combining a transparent base material (such as quartz or special glass) with metallic or polymer embossing patterns. This composite structure maintains optical transparency for UV radiation while providing the mechanical properties and surface patterns needed for effective embossing, expanding material selection possibilities.
Solution Approach 2:
The optical and mechanical parameters of the embossing roller material are optimized for specific UV wavelengths. By adjusting the material composition and thickness, the roller can be tailored to transmit specific UV wavelengths while maintaining the required mechanical strength and embossing performance, thereby expanding material versatility.
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 enhances dimensional accuracy, reduces maintenance costs, and improves the reproducibility and productivity of embossed structures by ensuring uniform crosslinking and minimizing thermal and mechanical issues.
Implementation Method 1
The embossing roller serves as a light guide for the coupled-in crosslinking radiation
Implementation Method 2
curing of an embossing mass acted upon by the embossing roller by the coupled out crosslinking radiation
Data Source
Figure 1a~1b
Figure 1c~1g
Figure 1h
AI summary
The invention relates to a method for embossing micro-structures and/or nano-structures.