Printing Roller Groove Layout to Prevent Release Paper Edge Lifting
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Solution Overview
Problem
Conventional reflective sheet manufacturing apparatuses result in a lifting phenomenon of the release paper edge due to air inflow, leading to adhesive hardening and increased defect rates, and fail to maintain optimal printing conditions.
Innovation Solution
The apparatus integrates release paper adhesive printing grooves on both sides of the printing roller, along with structures for tension control, roller gap adjustment, and reflective liquid tray positioning, ensuring proper adhesion and printing quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the release paper is attached only to the light-induced pattern area, then the manufacturing process is simple, but the release paper edge lifts due to air inflow during rolling and storage
Solution Approach 1:
The adhesive area on the reflective sheet is segmented into two distinct zones: a central light-induced pattern area and peripheral release paper adhesive patterns at both ends. This segmentation allows the release paper to be selectively adhered at multiple locations (both ends and center) rather than a single continuous area, preventing edge lifting while maintaining manufacturing feasibility through the printing roller's groove structure
Solution Approach 2:
The release paper adhesive patterns are printed on the reflective sheet before the release paper is attached. This preliminary action ensures that adhesive areas are pre-positioned at both ends of the reflective sheet, allowing the release paper to be properly secured at the edges before rolling and storage, thereby preventing subsequent lifting phenomena
2Device complexity
If the printing roller only has pattern printing grooves, then the printing unit structure is simple, but it cannot print both light-induced patterns and release paper adhesive patterns
Solution Approach 1:
The printing roller is designed with dual functionality by incorporating two types of grooves: pattern printing grooves for light-induced patterns and release paper adhesive printing grooves for adhesive patterns. This multi-functional design allows a single printing roller to perform both printing tasks sequentially or simultaneously, eliminating the need for separate printing mechanisms while maintaining structural simplicity
Solution Approach 2:
The pattern printing grooves and release paper adhesive printing grooves are merged into a single printing roller structure. Both types of grooves are formed on the outer circumference of the same roller, allowing the consolidation of multiple printing functions into one component, thereby reducing overall device complexity while achieving versatile printing capability
3Ease of operation
If the release paper is rolled with the reflective sheet without proper end adhesion, then the rolling process is easy, but air flows into the lifted space causing adhesive to harden and increasing defect rate
Solution Approach 1:
Release paper adhesive patterns are printed at both ends of the reflective sheet before the rolling process. This preliminary adhesion preparation ensures that the release paper is securely attached at the edges during rolling, preventing air from entering and causing adhesive hardening, thereby reducing defect rates while maintaining ease of operation
Solution Approach 2:
The adhesive reflective liquid that could potentially cause harm by flowing and creating defects is converted into a benefit by using it to create release paper adhesive patterns at both ends. These patterns serve as anchoring points that prevent the harmful lifting and air infiltration phenomena during rolling and storage
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
Prevents lifting of the release paper and maintains optimal printing conditions, resulting in high-quality reflective sheets with improved adhesion and extended storage life.
Implementation Method 1
when the printing roller rotates while a portion of a lower side the printing roller is immersed in the adhesive reflective liquid, the adhesive reflective liquid is applied to an outer peripheral surface of the printing roller
Implementation Method 2
a knife having an end in contact with the outer peripheral surface of the printing roller is installed on one side of the printing roller, thereby when the printing roller to which the adhesive reflective liquid is applied rotates, the adhesive reflective liquid applied to the outer peripheral surface of the printing roller is removed
Implementation Method 3
when the reflective sheet passes between the rubber roller and the printing roller, the adhesive reflective liquid remaining in the pattern printing grooves and the release paper adhesive printing grooves of the printing roller is transferred to the reflective sheet to be printed thereon
Implementation Method 4
a dryer installed on an upper portion of the structural frame to dry the reflective sheet on which the light-induced pattern and the release paper adhesive pattern are printed while passing therethrough
Implementation Method 5
a pair of lamination rollers configured to rotate in a direction where they are engaged with each other, thereby, the release paper is supplied between the pair of lamination rollers when the reflective sheet passes therethrough, so that the reflective sheet and the release paper are wound together on the winding roll in a state where they are laminated
Data Source
AI summary
In an apparatus for manufacturing an LED reflective sheet, release paper adhesive printing grooves are integrally formed on both sides of a printing roller having pattern printing grooves formed therein along an outer circumference thereof, such that when printing a light-induced pattern on the reflective sheet through the printing roller, a release paper adhesive pattern is also printed, thus both ends of the release paper are adhered to the release paper adhesive pattern during attaching the release paper to the reflective sheet, and thereby preventing an occurrence of a lifting phenomenon between the release paper and the reflective sheet.