Surface-adaptive UV-LED ink system with programmable wettability for multi-substrate digital printing

Abstract

A surface-adaptive UV-LED ink system (100) with programmable wettability for digital printing on multiple substrates, comprising: a surface-adaptive ink formulation module configured to deliver UV-curable inks with tunable wetting properties; a programmable wetting control module operable to dynamically adjust the surface tension properties of the ink in response to substrate-specific data; a multi-substrate sensing module comprising one or more sensors configured to sense the surface energy, texture, and material type of a substrate; a UV-LED curing module adapted to quickly and selectively cure the ink after deposition; a precision inkjet dosing module configured to eject ink droplets of variable size and velocity onto the substrate based on printing requirements; a central control and synchronization module configured to process sensor inputs, execute adaptive algorithms, and synchronize the operations of all system modules; and a real-time feedback and calibration module configured to monitor deposition performance, detect anomalies, and recalibrate system parameters during operation, The system as a whole enables autonomous, high-resolution and substrate-adapted digital printing across a wide range of material types without the need for manual reconfiguration.

Description

[0001] The present invention relates to the field of advanced digital printing technologies. More specifically, it concerns UV-LED ink systems designed for adaptive surface interaction and controlled wettability. The invention enables high-resolution compatibility with multiple substrates in modern printing applications.

[0002] In conventional digital printing, achieving consistent print quality on diverse substrates such as plastics, textiles, glass, and metals is a major challenge. Most ink formulations lack the ability to adapt to different surface energies and topographies, leading to problems such as poor adhesion, smearing, and uneven surfaces. This limits the efficiency and versatility of existing digital printing systems, especially in industrial and custom printing applications.

[0003] While conventional UV-curable inks are fast-drying and durable, they have shortcomings in dynamic surface compatibility. The fixed wettability and flow characteristics of such inks make them suboptimal for printing on variable substrates without pretreatment or multiple ink formulations. Furthermore, the inability to program color behavior leads to material waste, slower processing, and limited design options, especially for fine details or 3D-structured surfaces.

[0004] To overcome these problems, there is a growing need for an intelligent ink delivery system that can dynamically adapt its surface interaction properties in real time. A surface-adaptive UV-LED ink system with programmable wettability offers a solution by tailoring the ink's behavior to the specific properties of each substrate. This innovation eliminates the need for surface pretreatment, increases adhesion, and improves image fidelity—enabling efficient, high-quality digital printing on multiple substrates.

[0005] An object of the present disclosure is to enable high-quality digital printing on various substrates without changing the ink formulation.

[0006] Another object of the present disclosure is programmable wettability, which ensures optimal color spreading and adhesion to any surface.

[0007] Another object of the present disclosure is to eliminate the need for surface pretreatment and thus reduce time and processing costs.

[0008] Another subject of the present disclosure is UV-LED curing, which enables energy-efficient solidification of the ink at low temperatures.

[0009] Another subject of the present disclosure is the intelligent sensor technology, which enables automatic substrate detection and system adaptation.

[0010] Another object of the present disclosure is real-time feedback, which ensures consistent print quality and minimizes material waste.

[0011] Another object of the present disclosure is precise inkjet dispensing that enables high-resolution output on complex surfaces.

[0012] Another object of the present disclosure is a fully integrated control system that enables autonomous and scalable industrial printing.

[0013] The present invention relates to a surface-adaptive UV-LED ink system designed for high-quality digital printing on multiple substrates. It intelligently adapts to different material surfaces without the need to change the ink or treat the surface.

[0014] Another embodiment of the present invention is that the system uses a programmable wettability controller to change the surface tension of the ink in real time. This allows the ink to disperse optimally depending on the nature and energy profile of the substrate.

[0015] Another embodiment of the present invention is a multi-substrate sensor module that automatically detects the type and properties of the substrate. It enables seamless transitions between materials such as plastic, metal, fabric, or glass.

[0016] Another embodiment of the present invention is the UV-LED curing module, which enables rapid curing of the ink at low temperatures to maintain the integrity of the substrate. It ensures strong adhesion and durable finishes, even on heat-sensitive materials.

[0017] Another embodiment of the present invention is the surface-adaptive ink formulated with functional additives and reactive polymers. These enable dynamic interaction with different surfaces and ensure excellent print quality.

[0018] Another embodiment of the present invention is the precision inkjet metering module, which controls droplet volume, velocity, and positioning. It enables high-resolution printing with consistent ink flow on both flat and textured substrates.

[0019] Another embodiment of the present invention is a central control and synchronization module that manages real-time coordination between scanning, color adjustment, curing, and printing. This streamlines the process and reduces the need for manual intervention.

[0020] Another embodiment of the present invention is the real-time feedback and calibration module, which continuously monitors droplet behavior and surface coverage. It makes automatic adjustments to ensure consistent performance and minimize printing errors.

[0021] The present invention relates to a surface-adaptive UV-LED ink system with programmable wettability, designed for advanced digital printing applications. It integrates intelligent ink formulations, programmable surface interaction, and adaptive control to print seamlessly on a wide range of substrates. The system utilizes real-time sensing and feedback to optimize the ink's behavior for each surface, ensuring excellent adhesion and image quality. UV-LED curing ensures fast, energy-efficient solidification without damaging delicate materials. Surface-adaptive ink formulation module:

[0022] This module focuses on the development of UV-curable ink formulations with tunable surface interaction properties. The inks are developed with functional additives, surfactants, and reactive oligomers that allow the ink to modulate its wettability upon exposure to UV light or thermal triggers. These smart inks can self-tune their spreading behavior based on the chemical composition and surface energy of the substrate, ensuring optimal coverage and adhesion without manual intervention. Programmable module for controlling wettability:

[0023] This module regulates the programmable aspect of ink wettability. It contains an integrated control system that uses preset or sensor-driven inputs to activate ink modifiers at the molecular level. Through thermal, electrical, or photoinitiated signals, the system adjusts the ink's surface tension in real time during the printing process. This adaptability ensures precise droplet placement and prevents problems such as ink beading or overflow on different substrates. Multi-substrate detection module:

[0024] This module includes substrate detection sensors that detect the type, texture, and surface energy of the material being printed. Using spectroscopy, capacitive, or optical sensors, it collects surface data and transmits it to the ink control system. This allows the printing system to dynamically adjust the ink flow and surface interaction parameters to the specific material, enabling seamless transitions between substrates without manual adjustments or material-specific ink changes. UV LED curing module:

[0025] This module consists of a highly efficient UV LED array that rapidly cures the ink after application. Unlike conventional UV lamps, the LED configuration ensures targeted curing with low heat generation, making it suitable for heat-sensitive materials. The UV curing process is synchronized with the droplet application and substrate movement to ensure the ink retains its surface-adaptive properties until the desired surface interaction is achieved, after which it solidifies with high durability and resolution. Precision inkjet dispensing module:

[0026] This module is responsible for precise droplet ejection from high-resolution printheads. It features micronozzles that control droplet size, velocity, and trajectory based on inputs from the wettability and substrate measurement modules. The system can dynamically change droplet frequency and spacing to accommodate surface variations and pattern requirements. This enables high-resolution output with consistent quality on a wide variety of surfaces, including curved or textured surfaces. Central control and synchronization module:

[0027] This is the intelligent core of the system, which harmonizes the operation of all other modules. It executes adaptive algorithms that correlate substrate type, ink behavior, curing parameters, and droplet dynamics in real time. The module features a user interface for adjusting print parameters and supports industrial-scale operation automation. It ensures optimal timing and coordination between sensing, dispensing, and curing for efficient, continuous printing. Real-time feedback and calibration module:

[0028] To ensure quality and consistency, this module provides closed-loop feedback during printing. It uses image analysis, surface inspection cameras, and defect detection algorithms to monitor ink behavior after application. If deviations such as poor distribution, misalignment, or insufficient curing are detected, the system recalibrates parameters such as droplet volume, curing intensity, or ink formulation in subsequent passes. This ensures reliable print quality and minimizes waste.

[0029] The invention is explained again below with reference to the figure. It shows: Fig. : an illustration of a surface-adaptive UV-LED ink system (100) with programmable wettability for digital printing on multiple substrates.

[0030] Fig.illustrates a surface-adaptive UV-LED ink system (100) with programmable wettability for multi-substrate digital printing. The surface-adaptive UV-LED ink system with programmable wettability for multi-substrate digital printing operates through a highly integrated sequence of intelligent modules. First, the multi-substrate sensor module detects the type and surface properties—such as texture, material composition, and energy—of the incoming substrate using optical or capacitive sensors. This information is immediately forwarded to the central control and synchronization module, which analyzes the data and initiates coordinated actions throughout the system.Based on the substrate properties, the Programmable Wettability Control Module dynamically adjusts the surface tension of the specialty ink produced by the Surface-Adaptive Ink Formulation Module, allowing the ink to spread or retract optimally for each material type. At the same time, the Precision Inkjet Dispensing Module dispenses ink droplets with controlled size and velocity to ensure precise placement according to the desired design pattern. Once the ink is applied, the UV-LED Curing Module is activated to solidify the ink without overheating, maintain the integrity of the substrate, and lock in the set wetting profile. Throughout the printing process, the Real-Time Feedback and Calibration Module monitors droplet performance and surface coverage using imaging and sensor data, which is fed back to the control system to refine the printing parameters as needed.Together, these modules form a self-adapting, high-fidelity digital printing workflow that can handle different substrates with minimal manual intervention and excellent print consistency.

Claims

[1] A surface-adaptive UV-LED ink system (100) with programmable wettability for digital printing on multiple substrates, comprising: a surface-adaptive ink formulation module configured to deliver UV-curable inks with tunable wetting properties; a programmable wetting control module operable to dynamically adjust the surface tension properties of the ink in response to substrate-specific data; a multi-substrate sensing module comprising one or more sensors configured to sense the surface energy, texture, and material type of a substrate; a UV-LED curing module adapted to quickly and selectively cure the ink after deposition; a precision inkjet dosing module configured to eject ink droplets of variable size and velocity onto the substrate based on printing requirements; a central control and synchronization module configured to process sensor inputs, execute adaptive algorithms, and synchronize the operations of all system modules; and a real-time feedback and calibration module configured to monitor deposition performance, detect anomalies, and recalibrate system parameters during operation, The system as a whole enables autonomous, high-resolution and substrate-adapted digital printing across a wide range of material types without the need for manual reconfiguration. [2] The system (100) of claim 1, wherein the programmable wettability control module uses photoinitiated or thermal stimuli to change the surface tension of the ink in real time during deposition. [3] The system (100) of claim 1, wherein the multi-substrate sensor module includes optical, spectroscopic or capacitive sensors for accurate material detection and classification. [4] The system (100) of claim 1, wherein the UV LED curing module is configured to selectively emit targeted wavelengths for curing based on ink chemistry and substrate sensitivity. [5] The system (100) of claim 1, wherein the surface-adaptive ink formulation module contains intelligent additives such as surfactants, light-responsive polymers, or functionalized oligomers. [6] The system (100) of claim 1, wherein the precision inkjet dispensing module comprises high-resolution micronozzles capable of adjusting droplet frequency and pitch based on substrate topology. [7] The system (100) of claim 1, wherein the real-time feedback and calibration module uses surface mapping and error correction algorithms to improve print fidelity and reduce material waste. [8] The system (100) of claim 1, wherein the central control and synchronization module includes a user interface for programmable print configurations and supports integration with industrial automation systems.

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