Multi-face Plate Cylinder Transfer Apparatus
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Solution Overview
Problem
Existing transfer apparatuses with a single metal plate for embossing result in significant waste of transfer materials like gold or silver foil due to unused areas, as they lack multiple transfer faces to optimize material usage and reduce waste.
Innovation Solution
A transfer apparatus featuring a plate cylinder with multiple transfer faces and an impression cylinder, where the transfer material is carried in synchronization with the base material, utilizing each transfer face efficiently by adjusting the carrying action to minimize unused areas through controlled step-back movements and deceleration/acceleration processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single metal plate for embossing is used, then the device structure is simple, but the transfer material waste is significant
Solution Approach 1:
The metal plate for embossing is divided into multiple transfer faces (first, second, third transfer faces) spaced at different positions. Each transfer face can independently transfer the transfer material to the base material, allowing the same transfer material to be utilized multiple times through different faces, thereby reducing waste while maintaining structural feasibility
Solution Approach 2:
The invention transitions from a single-plane transfer mechanism to a multi-spatial transfer mechanism by arranging multiple transfer faces at different positions around the embossing cylinder. This spatial dimensionality change enables the transfer material to be processed multiple times through different faces, converting a linear single-use process into a multi-dimensional reusable process
2Productivity
If the carrying speed is increased to reduce unused transfer material, then the productivity improves, but the carrying stability deteriorates
Solution Approach 1:
The embossing process is organized into periodic cycles where the transfer material is carried forward at controlled speeds, undergoes embossing at specific positions, and then returns to its starting position. This periodic action allows for optimized speed control during different phases (forward carry, embossing, return), maintaining stability during critical operations while achieving high productivity through continuous cycling
Solution Approach 2:
The carrying mechanism employs dynamic speed control, adjusting the carrying speed according to the operational phase. During forward carrying and embossing operations, the speed is optimized for productivity, while during return movements and positioning, the speed is adjusted to ensure carrying stability and precision, creating a dynamically adapted carrying system
3Loss of substance
If the return distance due to step-back is reduced, then the transfer material utilization improves, but the carrying action complexity increases
Solution Approach 1:
The system performs preliminary positioning and speed adjustment actions before the main embossing operation. The transfer material is carried forward to the correct position, pre-positioned for embossing, and then the embossing operation is executed. This preliminary action ensures that when the return step-back occurs, the transfer material is already optimally positioned, reducing the required return distance and improving utilization without excessive complexity
Solution Approach 2:
The carrying system incorporates feedback control where the position and speed of the transfer material are continuously monitored and adjusted. Based on feedback from position sensors and operational status, the system automatically adjusts the carrying speed and return distance to optimize transfer material utilization while managing the complexity of the carrying action through intelligent control
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
The apparatus effectively utilizes the transfer material without wasting, stabilizes the carrying action, and improves yield by reducing the return distance due to step-back, thereby enhancing the efficiency and reducing production costs.
Implementation Method 1
a transfer apparatus in which a transfer material is transferred to a base material to be transferred using a plate cylinder and an impression cylinder
Data Source
Figure 1
Figure 2
Figure 3A~3H
AI summary
There is provided a transfer apparatus in which a transfer material can be effectively used without wasting and a return distance can be shortened in accordance with a carrying state of the transfer material so that carrying action of the transfer material is stabilized and yield may be improved. A plate cylinder 20 has two or more transfer faces, a distance between the transfer faces is three or more than a distance needed for transfer by one transfer face, a transfer material 6 is sequentially transferred to a base material to be transferred 7 by two or more transfer faces during one rotation of the plate cylinder 20, a control part 5 controls a step back to carry the transfer material 6 backwardly after finishing one rotation of the plate cylinder 20, so that an area to be used by the first transfer face during next rotation comes to an area adjacent to and on a downstream side in the carrying direction of an area of the transfer material 6 which has been used by the second transfer face during previous rotation.