Foil Stamping Die Edge Structure for Precise Pattern Boundaries

Solution Overview

Problem

Foil adherence to printing objects exceeds the edge of uneven patterns during foil stamping, leading to increased deviation between three-dimensionally formed portions and colored areas, deteriorating design properties.

Innovation Solution

A foil stamping die with a pattern-shape portion having a uniform thickness along its edge and protrusions to control foil adherence, ensuring the foil transfers only within the intended pattern boundaries.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If foil stamping is applied to transfer foil to printing object, then the printing object is colored and decorated, but the foil adheres to a range exceeding the edge of the uneven pattern, causing deviation between three-dimensionally formed portions and colored portions

Engineering Contradiction:

Improvealignment between colored portion and three-dimensionally formed portionVSAvoidfoil stamping process simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The foil stamping die is pre-designed with a constant thickness portion extending beyond the variable thickness portion. This preliminary structural arrangement ensures that during the foil stamping process, the foil is mechanically constrained to adhere only within the intended pattern area, preventing excessive adhesion before the actual stamping action occurs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The foil stamping die incorporates regions with different thickness characteristics: a constant thickness portion that extends beyond the pattern boundaries and a variable thickness portion that forms the uneven pattern. This local differentiation in thickness quality allows the die to simultaneously control foil adhesion boundaries while creating the desired three-dimensional pattern effect.

Inventive Principle:

Principle #3Local quality

2Productivity

If the foil adheres to a range greatly exceeding the edge of the pattern, then the foil transfer process is complete, but the design property of the printing object deteriorates

Engineering Contradiction:

Improvefoil transfer completenessVSAvoiddesign property of printing object

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The foil stamping die is pre-designed with a constant thickness portion extending beyond the variable thickness portion. This preliminary structural arrangement ensures that during the foil stamping process, the foil is mechanically constrained to adhere only within the intended pattern area, preventing excessive adhesion before the actual stamping action occurs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The foil stamping die incorporates regions with different thickness characteristics: a constant thickness portion that extends beyond the pattern boundaries and a variable thickness portion that forms the uneven pattern. This local differentiation in thickness quality allows the die to simultaneously control foil adhesion boundaries while creating the desired three-dimensional pattern effect.

Inventive Principle:

Principle #3Local quality

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

Enhances the design properties of the printing object by preventing foil from adhering beyond pattern edges, maintaining a high-grade appearance.

Implementation Method 1

a foil stamping die that can be pressed against a printing object, on which a foil is placed, to transfer the foil to the printing object while applying an uneven pattern to a surface of the printing object

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

a foil stamping die that can be pressed against a printing object

Methodology Applied

Scientific EffectPressure: Pressure Increase

Data Source

PatentUS20260097427A1Foil stamping die and method of manufacturing vehicle interior component

Publication Date: 2026.04.09 MORIROKU

AI summary

The present invention relates to a foil stamping die used for foil stamping, and a method of manufacturing a vehicle interior component using the foil stamping die. An object of the present invention is to provide a foil stamping technique capable of enhancing the design property of a printing object. In a foil stamping die capable of transferring a foil to the printing object while applying an uneven pattern to a surface of the printing object by pressing the die toward the printing object on which the foil is placed, a pattern-shape portion which is a portion corresponding to the uneven pattern is provided, and an edge of the pattern-shape portion has the same thickness over the entire area thereof.