Printed Relief Pattern Embossing via Digital Ink Deposition
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional embossing techniques require dedicated machinery and are costly due to the need for custom-made dies, leading to delays and increased effort in the post-printing process.
Innovation Solution
Integrating a digital printing system to create printed relief patterns that serve as embossing dies, allowing for rapid and cost-effective embossing during the normal printing workflow using technologies like LEP printing, which forms ink structures that can be used to deform media and create raised images.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional embossing machinery with custom dies is used, then embossing quality is maintained, but manufacturing cost and time increase significantly
Solution Approach 1:
The patent uses digital printing to create a relief pattern that copies the embossing design directly onto the printing surface. This digital copy eliminates the need for physical die manufacturing, reducing time while maintaining embossing quality through precise digital control of the relief structure.
Solution Approach 2:
The patent replaces the mechanical die system with a digitally printed relief pattern. Instead of using physical metal or plastic dies that require manufacturing and maintenance, the system uses inkjet-printed material layers that form the embossing structure directly during the printing process.
2Ease of manufacture
If separate embossing machinery is used, then embossing functionality is achieved, but device complexity and cost increase
Solution Approach 1:
The patent merges the embossing function with the printing function by integrating the relief pattern creation into the printing process itself. The same printing system that creates the visual image also creates the embossing structure, eliminating the need for separate embossing machinery.
Solution Approach 2:
The printing system is designed to perform multiple functions: it prints the visual image and simultaneously creates the embossing relief pattern. This multi-functional approach eliminates the need for dedicated embossing equipment, reducing overall device complexity while maintaining embossing capability.
3Manufacturing precision
If post-printing embossing run is performed, then embossed images are created, but manufacturing time and effort increase
Solution Approach 1:
The patent performs the embossing structure creation during the printing process itself, rather than as a subsequent post-printing step. The relief pattern is built up layer by layer as part of the printing sequence, eliminating the need for a separate post-printing embossing run and improving overall manufacturing speed.
Solution Approach 2:
The patent maintains continuous useful action by integrating embossing structure creation into the printing process. Instead of stopping printing to perform separate embossing operations, the system continuously builds both the visual image and the embossing relief structure in a single uninterrupted printing cycle.
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 eliminates the need for separate embossing machines and dies, reducing costs and time by enabling low-cost, rapid embossing runs with sharper images and the ability to change designs quickly, while maintaining high-quality embossed features.
Implementation Method 1
an inkjet system is used to deposit material to form a printed relief pattern on the media
Implementation Method 2
The printed relief pattern is then used to deform the media to create the embossed image
Data Source
AI summary
An embossing apparatus includes an embossing die that includes a printed relief pattern made up of multiple layers of a deposited material. A resilient surface presses media against the embossing die such that embossed features corresponding to the embossing die are formed in the media. A method for embossing media includes forming an embossing die by depositing multiple layers of ink on a impression layer to form a relief pattern and pressing media against the embossing die to transfer the relief image to the media.