Toner Layer Thickness Variation for Foil Stamping Texture
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Solution Overview
Problem
Current methods for creating foil-stamped printed matter using a toner or ink layer as a foundation layer cannot replicate the texture achieved by traditional foil stamping with a foil plate, as the toner or ink layers are typically flat, lacking concave and convex portions.
Innovation Solution
A system that generates print data to form toner or ink layers with varying thicknesses, allowing for the creation of both thick and thin areas, enabling the formation of concave and convex portions when foil is stamped onto these layers, mimicking the texture achieved by foil plate stamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If foil stamping is performed on a flat toner layer or ink layer, then foil-stamped printed matter can be readily created at low costs, but the surface of the foil becomes flat and cannot have concave and convex portions formed therein, failing to achieve the same texture as traditional foil plate stamping
Solution Approach 1:
The patent applies local quality by creating non-uniform toner layer thickness in specific areas. The control device generates print data that causes the toner layer to have relatively large thickness portions and relatively small thickness portions within the foil stamping area. This local variation in thickness enables the foil to form concave and convex portions when stamped, achieving the desired texture while maintaining cost advantages
Solution Approach 2:
The patent changes the physical parameter of toner layer thickness from uniform to non-uniform. By controlling the printing conditions and using multiple printing passes with different image data, the system varies the toner layer thickness parameter across different regions, enabling the foil stamping process to create textured surfaces without requiring traditional foil plates
2Manufacturing precision
If a foil plate is used for foil stamping to create concave and convex portions, then the desired texture can be achieved, but the device becomes large in size and requires expensive specialized equipment
Solution Approach 1:
The patent uses the printing device to create a toner layer pattern that copies or replicates the function of a traditional foil plate. Instead of using a physical foil plate with raised surfaces, the system prints image data that creates corresponding thickness variations in the toner layer, which then guides the foil stamping process to produce the same textured effect
Solution Approach 2:
The patent replaces the mechanical foil plate system with a printing-based system. Instead of using a physical foil plate that mechanically imprints texture, the system uses a printing device to create a toner layer with varying thickness, which then chemically or thermally bonds the foil in a pattern that replicates the desired texture without requiring the complex mechanical foil plate apparatus
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 allows for the creation of foil-stamped printed matter with a texture similar to that produced by traditional foil plate methods, enhancing the visual appeal and reducing production costs by enabling in-house foil stamping without the need for specialized equipment.
Implementation Method 1
a printing device that forms a toner layer or an ink layer on a paper sheet
Implementation Method 2
a foil stamping device that performs foil stamping on the toner layer or the ink layer
Data Source
AI summary
A printed matter foil stamping system includes: a printing device that forms a toner layer or an ink layer on a paper sheet in accordance with print data; and a foil stamping device that performs foil stamping on the toner layer or the ink layer, wherein the printing device or a control device that controls the printing device includes a hardware processor that generates print data capable of forming a portion in which a thickness of the toner layer or the ink layer is relatively large and a portion in which the thickness is relatively small in an area in which foil stamping is to be performed, and, in accordance with the print data, the printing device forms the toner layer or the ink layer having a portion with a relatively large thickness and a portion with a relatively small thickness on the paper sheet.