Simulated Embossing via Image Processing and Clear Ink
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Solution Overview
Problem
Embossed printing is expensive due to the cost and time required for creating embossing plates and applying heat and pressure, making it inefficient for mass production.
Innovation Solution
Simulating embossed prints using image processing techniques combined with clear dry ink or spot varnish to replicate the tactile feel without the need for specialized equipment or embossing plates, utilizing a printer adapted to apply these finishes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional embossing plates and heat pressure equipment are used, then tactile embossed effect is achieved, but production cost and time increase
Solution Approach 1:
The patent uses image processing to create a visual copy of the embossed effect through shading and highlighting, while a clear coating provides a tactile copy of the embossed surface. This eliminates the need for physical embossing plates while maintaining both visual and tactile characteristics of embossed printing.
Solution Approach 2:
The patent replaces the mechanical embossing system (plates, heat, and pressure) with a printing system that applies pigments and clear coatings. This substitution eliminates complex mechanical equipment while achieving similar tactile and visual effects through material deposition.
2Manufacturing precision
If embossing plates are created, then embossed printing quality is improved, but device complexity and cost increase
Solution Approach 1:
The patent creates visual copies of embossed surfaces using image processing algorithms that simulate lighting and shadows. Combined with clear coating application, this copying approach reproduces both the appearance and tactile feel of embossed printing without requiring physical embossing plates or specialized equipment.
Solution Approach 2:
The patent substitutes the mechanical embossing system with a digital printing and coating system. Image processing software generates the embossed visual effect, and a standard printer with clear coating capability replaces specialized embossing equipment, significantly reducing device complexity.
3Manufacturing precision
If heat and pressure are applied with dies, then embossed effect is achieved, but production time and energy consumption increase
Solution Approach 1:
The patent replaces the thermal-mechanical embossing process with a printing and coating process. Instead of applying heat and pressure with dies, the system uses digital printing to deposit pigments and clear coating to create the embossed effect, eliminating the time-consuming heating and pressing steps while maintaining production quality.
Data Source
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AI summary
Image processing is used to simulate the appearance of an embossed print. The application of clear dry ink or spot varnish to the print generates the tactile feel of an embossed print. Embodiments thus provide a technique that simulates the effect of an embossed print without the need for plates or specialized equipment, other than a printer that is adapted to apply clear dry ink or spot varnish.