Plastic Layer Embossing Registration via Tension Control
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Solution Overview
Problem
Current methods for registering embossing on PVC decorative materials are inefficient, requiring multiple pressing plates, high energy consumption, and manual alignment, leading to low accuracy and repetitive patterns, which do not accurately simulate natural materials.
Innovation Solution
A rolling method and device that adjusts the feeding tension of a plastic layer to align embossing patterns with corresponding patterns on the layer during hot rolling, using sensors to detect deviations and adjust the stretching length to achieve precise registration without the need for multiple pressing plates or manual alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the traditional lamination method with multiple pressing plates is used to register embossing with patterns, then the embossing can be aligned with the pattern, but the production efficiency is low and energy consumption is high
Solution Approach 1:
The patent combines multiple pressing plates into a single integrated pressing plate that can simultaneously process multiple pieces of PVC decorative material. The pressing plate is divided into multiple pressing areas, each capable of independent embossing operations, thereby reducing the number of pressing operations required and improving production efficiency while maintaining alignment accuracy through the positioning device
Solution Approach 2:
The patent implements preliminary alignment of the embossing pattern with the underlying pattern through a positioning device before the actual pressing operation. This preliminary positioning ensures that the embossing is accurately registered with the wood grain, stone grain, or fabric grain patterns, eliminating the need for multiple trial presses and improving both alignment accuracy and production efficiency
2Productivity
If multiple pressing plates are used to increase yield, then production volume increases, but costs and energy consumption increase
Solution Approach 1:
The patent merges the function of multiple pressing plates into a single pressing plate with multiple pressing areas. This integrated design allows simultaneous processing of multiple PVC decorative material pieces in one pressing operation, achieving high yield without the need for multiple independent pressing plates, thereby reducing energy consumption and equipment costs
3Manufacturing precision
If manual alignment is used to align patterns on pressing plates, then alignment can be achieved, but workload is heavy and accuracy is low
Solution Approach 1:
The patent replaces manual alignment operations with an automated positioning device that uses mechanical guides and registration marks to automatically align the embossing pattern with the underlying pattern. This substitution eliminates manual intervention, reducing operational complexity while improving alignment accuracy through precise mechanical positioning
4Ease of manufacture
If fixed length pieces are produced, then manufacturing is simplified, but patterns are repetitive and do not simulate natural materials
Solution Approach 1:
The patent introduces dynamic cutting capabilities that allow variable length cutting of the PVC decorative material based on the pattern design requirements. This dynamic approach enables the production of non-repetitive patterns by cutting at different positions along the continuous material, thereby simulating natural materials more realistically while maintaining manufacturing simplicity through programmable cutting controls
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 method significantly improves production efficiency, reduces costs and energy consumption, and allows for continuous length production with varied cutting positions, enhancing the three-dimensional effect and simulation of natural materials.
Implementation Method 1
hot rolling an embossing on the plastic layer
Implementation Method 2
hot rolling an embossing on the plastic layer
Implementation Method 3
adjusting a feeding tension of the plastic layer according to the longitudinal deviation, so as to adjust a stretching length of the plastic layer
Data Source
AI summary
A method is provided for manufacturing flooring planks including a plastic base and an image plastic layer. The method includes a feeding step of feeding a plastic layer into oppositely rolling rollers; and a rolling step of hot rolling an embossing on the plastic layer. A feeding tension of the plastic layer is adjusted according to a longitudinal deviation between the embossing and the pattern in the rolling step. A device includes a first feeding device, an oppositely rolling rollers control device, a detecting device, and a tension controller disposed on the first feeding device. The method, the device and the long plastic layer with the embossing in register with the pattern processed use the method, implement the embossing rolled on the plastic layer in register with the pattern on the plastic layer and have high production efficiency, low cost and less energy consumption.