Film Web Guide Device for Hologram Embossing
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Solution Overview
Problem
Existing flat embossing printing machines face challenges in achieving optimal image positioning and tension adjustment for multiple image foil webs during hologram embossing, particularly for high-security features like notes of value and ID cards, due to limitations in guiding and positioning systems.
Innovation Solution
A film web guide device with individual, controllable guide paths and vacuum tensioning systems allows for precise adjustment of each image foil web in the X and Y directions, using adjustable lateral guide elements and image mark sensors to maintain optimal tension and positioning without contact on the sensitive side, ensuring error-free embossing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single wide suction brake and guide wall is used for all film webs, then the tension of film webs can be regulated with adjustable negative pressure, but optimal image positioning in X and Y directions cannot be achieved for each individual web
Solution Approach 1:
The single guide wall is divided into multiple individual guide paths, each assigned to a specific film web. Each guide path has its own suction channel and vacuum source, enabling independent tension control for each web while maintaining the ability to regulate tension across all webs simultaneously.
Solution Approach 2:
Each individual guide path is equipped with its own suction channel and vacuum source, creating locally optimized conditions for each film web. This allows different tension levels to be applied to different webs based on their specific requirements, while each guide path maintains the capability for precise image positioning through its dedicated vacuum control.
2Manufacturing precision
If contact guide elements are used to position film webs, then positioning can be achieved, but the sensitive embossed layer side of the foil webs is contacted and potentially damaged
Solution Approach 1:
The mechanical contact-based guide elements are replaced with a vacuum-based guidance system. Suction channels create a vacuum field that holds the film webs in the correct position without physical contact, eliminating the risk of damage to the sensitive embossed layer while maintaining precise positioning capability.
Solution Approach 2:
A vacuum field acts as an intermediary between the guide system and the film webs. Instead of direct mechanical contact, the vacuum suction creates a holding force that positions the webs without touching them, thereby protecting the sensitive surface while achieving the required positioning precision.
3Productivity
If multiple film webs of different types with different web widths and lengths are conveyed simultaneously, then productivity increases, but guiding and positioning becomes more complex
Solution Approach 1:
The guidance system is segmented into multiple independent guide paths, each dedicated to a specific film web. This segmentation allows each web to be guided and positioned independently according to its specific dimensions and requirements, enabling the simultaneous conveyance of multiple different web types without creating a tangled or confused guidance system.
Solution Approach 2:
Each guide path is designed as a universal module that can handle different web dimensions and types. The standardized structure of guide paths with integrated suction channels and vacuum sources allows the same basic design to accommodate various film web configurations, reducing overall system complexity while maintaining the capability to handle diverse web types simultaneously.
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 solution enables precise, error-free positioning and tension control for all image foil webs, enhancing embossing quality and performance by minimizing lateral deviations and maintaining optimal tensile stress, thus supporting high-quality hologram embossing across the entire embossing table.
Implementation Method 1
The individual guideways contain suction channels (16, 17) and have a smooth, low-friction surface (12) with suction openings (14), which are connected to controllable vacuum sources (13.1-13.4) for the independent setting of vacuum pi and braking force zfi on each individual guideway (11i).
Implementation Method 2
The individual guideways contain suction channels (16, 17) and have a smooth, low-friction surface (12) with suction openings (14)... The film must be guided without distortion, hull formation, creases and offsets, have a smooth surface
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
For each film web, the embossing machine comprising a film web guide device (2) for a plurality of film webs (6), which are guided from unwinding reels over a die (3) on a flat bed press, has film drawing devices behind the die and individual, long, central symmetrically configured guide webs (11.1, 11.2, 11.3), which can be set in the transverse direction Y relative to the drawing direction X, as film tensioning devices in front of the die. The guide webs have a smooth, low-friction surface (12) with suction openings (14), which are connected to controllable negative pressure sources (13.1, 13.2, 13.3) for the independent setting of the negative pressure (pi) and brake force (zfi) at each individual guide web (1 Ii). To this end, each picture film web (6i) is associated with a picture mark sensor (15i) between the film drawing device (9i) and the guide web (1 Ii) and also with settable lateral guide elements (30) provided on both sides on low-friction diverting elements (31, 32) directly in front of the guide webs and behind the die (3), wherein said lateral guide elements can guide the picture film webs centered on the guide webs. In this way, each picture film web (6i) can be optimally set for the picture marks in the X and Y directions while the machine is running, thereby minimizing picture position errors.