Laminating Body Imprinted Structure for Foil Embossing
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Solution Overview
Problem
The existing methods for manufacturing laminating bodies with structured surfaces, such as embossings, require elaborate equipment and processes like milling or etching, leading to high costs, long production times, and limited flexibility, especially for small batches or urgent orders.
Innovation Solution
A laminating body with an imprinted structure that embosses into the foil in mirror-image form during lamination, using a thermally stable lacquer and printing techniques like screen or UV offset printing, allowing for simpler, faster, and more cost-effective production without adhering to the foil, enabling on-site customization and reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If milling or etching is used to create structured laminating bodies, then the embossed structures are precise and durable, but the production costs are high and production time is long
Solution Approach 1:
The patent uses printing technology to create a copy of the embossed structure on the laminating body surface. Instead of physically milling or etching the structure, a printable layer is applied and printed with the desired embossed pattern, which is then transferred to the foil during lamination. This copying approach maintains structural precision while dramatically reducing production time and cost.
2Manufacturing precision
If elaborate production equipment is used for milling or etching, then the embossed structures meet specifications, but the device complexity increases and flexibility decreases
Solution Approach 1:
The patent replaces the mechanical milling and etching systems with a printing-based system. Instead of using complex mechanical tools to physically remove or deform material, the invention uses printing technology to deposit a structured layer that creates the embossed effect. This substitution simplifies the production equipment while maintaining the quality of the embossed structures.
3Ease of manufacture
If traditional milling or etching methods are used, then the laminating body can be manufactured, but the production time and delivery time are long
Solution Approach 1:
The patent applies a printable layer to the laminating body in advance, which can then be quickly printed with the desired embossed pattern. This preliminary preparation allows the actual embossing to be done rapidly using printing technology, significantly reducing production time compared to traditional milling or etching methods while maintaining ease of manufacture.
4Adaptability or versatility
If laminating bodies are frequently changed for small batches, then customization is possible, but the production costs increase
Solution Approach 1:
The printing-based embossing system allows for dynamic and flexible customization. The printable layer can be quickly reprinted with different embossed patterns without requiring physical retooling or remanufacturing of the laminating body. This dynamic approach enables cost-effective production of small batches with customized embossed structures, as the printing process can be rapidly adjusted to different designs.
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 significantly reduces production time and costs, enhances flexibility, and ensures confidentiality of embossed data, while maintaining the structural integrity and heat resistance necessary for lamination, making it suitable for small batches and urgent orders.
Implementation Method 1
a pressure area of the laminating body has an imprinted structure which is configured such that the structure incorporates into the foil upon lamination an embossing corresponding in mirror-image form to the structure
Implementation Method 2
the structure is sufficiently heat-resistant so as not to be damaged by a heating of the pressure area that might be required for lamination
Data Source
AI summary
A laminating body for laminating a foil onto a substrate includes a pressure area on which there is imprinted a structure which forms an embossing in the foil upon lamination of the foil onto the substrate.