Flexible Mold Catenary Profile for Relief Layer Application
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Solution Overview
Problem
Existing methods for applying a relief layer on a substrate often result in air inclusions and irregularities due to the use of rigid molds, and bending the substrate to accommodate these molds can lead to deformation and breakage of the relief layer.
Innovation Solution
A method using a flexible mold with a catenary profile that is gradually brought into contact with the substrate, maintaining a consistent catenary shape throughout the process to avoid air inclusions and substrate deformation, while ensuring the substrate remains flat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rigid mould is used to apply the relief layer, then the mould can maintain its shape and provide precise relief patterns, but air inclusions and bubbles develop leading to irregularities in the relief
Solution Approach 1:
The patent employs a flexible mould made of elastomeric material that can deform during the application process. This flexibility allows the mould to conform to the substrate surface and eliminate air inclusions while maintaining the relief pattern precision through the material's elastic recovery properties.
Solution Approach 2:
The patent changes the physical state and properties of the mould from rigid to flexible by selecting elastomeric materials with specific durometer values. This parameter change enables the mould to adapt its rigidity during different stages of the process - flexible during application to avoid air traps, and sufficiently rigid when cured to maintain pattern precision.
2Ease of operation
If the substrate is bent to accommodate a rigid mould, then the mould can be brought into contact with the liquid layer, but the substrate must be brought back to its original flat shape requiring complicated machinery and likely leading to deformation of the relief
Solution Approach 1:
Instead of bending the substrate to accommodate the mould, the patent inverts the approach by making the mould flexible to accommodate the flat substrate. This eliminates the need for complex substrate manipulation machinery while achieving complete contact between the mould and liquid layer.
3Manufacturing precision
If the substrate is bent after curing to return to flat shape, then the relief layer can be applied, but this would lead to deformation and breakage of the relief layer
Solution Approach 1:
The patent reverses the conventional approach by keeping the substrate flat and making the mould flexible. This eliminates the need to bend the substrate after curing, thereby preventing deformation and breakage of the relief layer while still achieving precise relief application.
Solution Approach 2:
The flexible elastomeric mould can be deformed during application and then returns to its original shape, allowing the substrate to remain flat throughout the process. This protects the cured relief layer from mechanical stress and potential breakage.
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 prevents air inclusions and deformation of the relief layer, ensuring a smooth and accurate application of the relief layer without compromising the substrate's integrity.
Implementation Method 1
the profile of the mould is a catenary. Upon contact of the mould with the surface, the profile of the mould is kept to be the same catenary
Implementation Method 2
curing the liquid layer while the mould is in contact with the curable liquid
Data Source
Figure 1A~1C
Figure 2A~2C
Figure 3
AI summary
The invention relates to a method and an apparatus for applying a layer (2) having a relief on a substrate (1), comprising the steps of securing the substrate, applying a layer of a curable liquid (2) on the substrate (1), bringing a mould (3) having a relief being the negative of the relief to be provided on the substrate, into contact with a part of the upper surface of the liquid layer (2), curing the liquid layer while the mould is in contact with the liquid and separating the mould (3) from the substrate (1), wherein initially the mould (3) is brought into contact with the liquid in a bent position while the substrate (1) is kept flat and subsequently the mould is brought into contact over an increasing surface area keeping the mould in a bent position until the complete liquid layer (2) is in contact with the mould (3). This method provides the gradual bringing into contact of the mould with the fluid layer on the substrate, avoiding any air inclusions.