Roll-to-roll polymer shim embossing tool with strippable release layer

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Solution Overview

Problem

Existing methods for manufacturing image embossing tools face challenges such as difficulty in matching curvature, maintaining precise and uniform surface profiles, especially for complex structures with deep 3D profiles, and the inability to produce multiple embossing tools simultaneously.

Innovation Solution

A polymer shim is created using a roll-to-roll process with a strippable composition, allowing for the production of a wide format embossing tool with a uniform surface profile and low defect rate, involving a master mold, embossable composition, and a joining process to form seamless shims.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple electroforming steps are used to create embossing tools, then the surface profile precision can be improved, but the manufacturing complexity and time increase significantly

Engineering Contradiction:

Improvesurface profile precisionVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent uses a master mold to create multiple copies (impressions) simultaneously in a single electroforming step. The master mold contains multiple patterns arranged in a matrix, and each impression captures one pattern. This copying approach eliminates the need for multiple sequential electroforming steps while maintaining high surface profile precision across all copies.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent segments the master mold into multiple independent pattern areas arranged in a matrix configuration. Each segment can be independently replicated in the impressions, allowing parallel production of multiple embossing tools from a single master mold in one electroforming cycle.

Inventive Principle:

Principle #1Segmentation

2Productivity

If a cylindrical embossing tool is used, then continuous embossing is enabled, but the curvature matching between stamper and embossable material becomes difficult

Engineering Contradiction:

Improvecontinuous embossing capabilityVSAvoidcurvature matching precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Instead of curving the stamper to match the cylindrical embossable material, the patent inverts the approach by using a flat master mold that creates flat impressions. The embossing tool is then formed by electroforming onto the flat impressions, eliminating the need for curved stampers and complex curvature matching while still enabling continuous embossing on cylindrical substrates.

Inventive Principle:

Principle #13The other way round (Inversion)

3Shape

If deep 3D profiles are embossed, then the embossing tool complexity increases, but the separation of electroforms becomes difficult

Engineering Contradiction:

Improve3D profile depthVSAvoidelectroform separation ease

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The patent introduces a release layer as an intermediary between the master mold and the electroformed impressions. This release layer facilitates easy separation of the impressions from the master mold even when deep 3D profiles are involved. The release layer prevents excessive adhesion while still allowing precise replication of complex geometries, solving the separation difficulty without compromising profile depth.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Strength

If metal electroforms are used, then durability is improved, but the separation from mandrel and rejoining of pieces becomes difficult

Engineering Contradiction:

Improveembossing tool durabilityVSAvoidseparation and rejoining ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent creates multiple metal electroform copies from a single master mold in parallel. Each electroform is a separate, complete embossing tool that can be independently handled, tested, and installed. This eliminates the need to separate and rejoin pieces, as each copy is a standalone functional unit with the required durability.

Inventive Principle:

Principle #26Copying

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 enables the efficient production of embossing tools with precise and uniform surface profiles, even for complex structures, and allows for the mass production of multiple embossing tools with reduced defects and seamless integration.

Implementation Method 1

A roll-to-roll process is provided for the production of a polymer shim. The process includes the steps of: (a) coating an embossable composition onto a substrate; (b) embossing the coated composition; and (c) curing the embossed composition.

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 2

The process includes the steps of: (a) coating an embossable composition onto a substrate; (b) embossing the coated composition; and (c) curing the embossed composition.

Methodology Applied

Scientific EffectUV curing: Photopolymerisation

Data Source

PatentUS7470386B2Roll-to-roll embossing tools and processes

Publication Date: 2008.12.30 E INK CORP

AI summary

The invention is directed to a polymer shim and a roll-to-roll process for its manufacture.