Structuring Film Embossing for Decorated Substrates
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Solution Overview
Problem
Existing methods for producing structures on substrates are costly for mass production and inefficient for small quantities, as they require multiple sample press sheets and high-cost patterning films.
Innovation Solution
A method involving the creation of a structuring film with a three-dimensional structure using digital printing, which can be optimized and transferred to a substrate for embossing, allowing for quick and inexpensive production of samples and later scaled up using an optimized press plate for larger quantities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If structuring film is used for producing structures on substrates, then small production runs can be handled flexibly, but the cost is too high for mass-produced products
Solution Approach 1:
The patent segments the production process into two distinct phases: a development phase using structuring film for small batches and sample creation, and a mass production phase using press plates for large quantities. This segmentation allows each method to be used where it is most effective, resolving the contradiction between flexibility for small runs and cost-effectiveness for mass production
Solution Approach 2:
The patent applies preliminary action by using structuring film to create and optimize structure designs before committing to expensive press plate production. The structuring film serves as a preliminary, low-cost prototype that allows design validation and optimization before mass production tools are manufactured
2Manufacturing precision
If multiple test press plates are produced to optimize structure, then structure-decor matching can be achieved, but time and cost are significantly increased
Solution Approach 1:
The patent uses digital scanning and file-based copying to transfer structure designs between the structuring film and press plate production. By scanning the optimized structuring film and saving it as a digital file, the design can be precisely reproduced on press plates without manual remaking, significantly reducing time and iteration costs while maintaining manufacturing precision
Solution Approach 2:
The patent replaces the mechanical trial-and-error process of physically making and testing multiple press plates with a digital workflow. The structure is scanned, saved as a file, and used to generate press plate production data, substituting physical iterations with digital information transfer and reducing both time and material waste
3Ease of manufacture
If press plates are produced in advance for mass production, then cost per unit is reduced, but inventory costs increase and demand uncertainty remains
Solution Approach 1:
The patent changes the production parameter from batch size to on-demand timing. Press plates are manufactured only after the structure design is finalized and validated through structuring film testing, and only when sufficient demand is confirmed. This parameter change allows the system to maintain low per-unit costs through press plate production while avoiding unnecessary inventory accumulation
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 enables cost-effective production of substrates with coordinated decor and structure, optimizing costs by only producing press plates when demand is justified, reducing inventory and ensuring precise replication of structures across quantities.
Implementation Method 1
printing the structure onto a structure-forming film
Implementation Method 2
embossing the structure onto a substrate with the decor using the structure-forming films
Data Source
Figure 1
AI summary
The invention relates to a method for producing structures on a substrate. To ensure a fast and cost-effective method for producing structures on a substrate, a method comprising the following steps is provided: presenting a decor provided with a structure, scanning the decor and the structure in separate files, printing the decor onto a substrate, printing the structure onto a structuring foil, embossing the structure onto a substrate provided with the decor using the structuring foils, optionally optimizing the structure and reprinting the structure onto a structuring foil and embossing the structure onto a substrate provided with the decor using the structuring foil, transferring the optionally optimized structure onto an embossing sheet.