Laminator Edge Wrapping for Sign Registration
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Solution Overview
Problem
Conventional methods for manufacturing multi-panel guide signs are time-consuming, labor-intensive, and costly, particularly due to the need for expensive screens in screen printing and the risk of cutout indicia peeling or creating waste, leading to inadequate performance and increased raw material costs.
Innovation Solution
The method involves digitally printing images on optically active materials, aligning and affixing them to substrates using a laminator with improved alignment tools and edge wrapping to ensure accurate registration and durability, reducing labor and material waste while enhancing optical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If screen printing is used to print indicia on retroreflective sheeting, then multi-color indicia can be produced, but expensive screens must be made for each individual sign
Solution Approach 1:
The patent uses digital imaging technology to create digital copies of sign designs and prints them directly onto retroreflective sheeting using inkjet or similar digital printers. This eliminates the need for physical screen-making while maintaining the ability to produce multi-color indicia, thereby reducing manufacturing costs while preserving design versatility
Solution Approach 2:
The patent changes the printing method from screen printing to digital printing, which allows for variable parameter control including color mixing, resolution adjustment, and design modification without requiring new screens. This parameter change enables cost-effective production of multi-color indicia with full adaptability
2Ease of operation
If cutout indicia are used on retroreflective sheeting, then indicia can be applied to signs, but the cutout indicia may peel or create waste
Solution Approach 1:
Instead of cutting physical indicia shapes from sheeting, the patent uses digital printing to create indicia directly on the sheeting surface. This copying approach eliminates the peeling problem associated with cutout indicia while maintaining ease of application, and reduces material waste from cutting operations
Solution Approach 2:
The patent applies printed indicia directly onto the thin film structure of retroreflective sheeting using digital printing technology. This creates a integrated, peel-free indicia application that maintains the integrity of the sheeting while achieving the desired sign content
3Ease of manufacture
If manual alignment methods are used for multi-panel signs, then panels can be assembled, but alignment precision is insufficient
Solution Approach 1:
The patent uses digital imaging to create precise digital templates and guides for panel alignment. These digital copies provide reference markings and registration features that enable accurate alignment of multi-panel signs, overcoming the limitations of manual alignment methods
Solution Approach 2:
The patent replaces manual mechanical alignment methods with an automated optical alignment system that uses light sources, sensors, and digital image processing. This substitution provides precise measurement and adjustment capabilities for achieving accurate indicia registration across multiple panels
4Ease of manufacture
If conventional lamination methods are used for optically active sheeting, then sheeting can be applied to substrates, but edge-related issues and peeling occur
Solution Approach 1:
The patent applies preliminary edge preparation and treatment before lamination, including edge sealing, adhesive application optimization, and alignment verification. These preliminary actions prevent edge-related issues and peeling during subsequent lamination and service life
Solution Approach 2:
The patent optimizes lamination parameters including temperature, pressure, adhesive type, and bonding time to achieve durable edge-to-edge lamination. By carefully controlling these parameters, the patent eliminates peeling issues while maintaining ease of application
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 manufacturing time and costs, minimizes human error, ensures consistent optical orientation, and improves sign durability by eliminating edge-related issues and peeling, resulting in uniform and efficient signage production.
Implementation Method 1
a light source that emits light rays and that is positioned under the conveyor so that the light rays propagate upward through the conveyor toward the one or more substrates on the conveyor; wherein the one or more substrates have a degree of opacity that is greater than a degree of opacity of the optically active sheeting such that the light rays emitted by the light source cast a shadow of a proximal edge of the substrate onto the optically active sheeting
Implementation Method 2
an adhesive-coated major surface of the optically active sheeting faces the one or more substrates... manually press the adhesive-coated major surface of the optically active sheeting onto the substrate to adhere together the optically active sheeting and the substrate
Data Source
AI summary
The present application generally relates to methods, materials, and equipment for manufacturing a signs. Some embodiments of the present application relate to methods of manufacturing a digitally printed, multi-panel sign. Some embodiments of the present application relate to a laminator for use in laminating optically active sheeting to a substrate.