Colorful Metal Patterns via Anodizing and Colorless Ink Masking
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Solution Overview
Problem
Existing methods for printing patterns on metal surfaces using UV-cured ink face issues with adhesion, as the ink tends to peel off easily due to high surface tension and the use of harmful cross-linking agents, and colored inks have poor long-term adhesion and environmental impact.
Innovation Solution
A method involving a first and second anodizing process on a metal substrate to form anodic oxide layers, followed by coating colorless UV-cured ink as a pattern mask and then a metal film, which enhances adhesion and durability, using environmentally friendly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If UV-cured ink is printed on metal surface, then patterns can be formed on metal, but the ink aggregates and peels off due to poor adhesion
Solution Approach 1:
The metal surface undergoes anodizing treatment before printing to pre-establish a porous oxide layer structure that will enhance ink adhesion. This preliminary surface modification creates optimal conditions for subsequent ink deposition without requiring harmful cross-linking agents.
Solution Approach 2:
The anodic oxide layer serves as an intermediary between the metal substrate and the UV-cured ink. This intermediate layer provides a porous structure that mechanically interlocks with both the metal base and the ink, significantly improving adhesion without requiring chemical cross-linking agents.
2Reliability
If cross-linking agents are used to improve adhesion, then ink adhesion increases, but environmental pollution increases due to harmful chemicals
Solution Approach 1:
The harmful cross-linking agents are completely removed from the printing system. Instead, the patent relies on the physical-chemical properties of the anodic oxide layer and UV curing to achieve adhesion without any environmentally harmful chemical additives.
Solution Approach 2:
The patent changes the surface parameters of the metal substrate through anodizing, creating a porous oxide layer with specific surface area and chemical properties that enable adhesion without harmful agents. The UV curing process also changes the chemical state of the ink from liquid to solid, locking it in place.
3Ease of manufacture
If colored UV-cured ink is used, then color patterns are achieved, but adhesion decreases and colors fade over time
Solution Approach 1:
The anodic oxide layer is formed before applying colored ink, pre-establishing a high-adhesion surface that can support color pigments without fading. This preliminary surface preparation ensures that the colored ink will maintain its adhesion and color intensity over time.
4Reliability
If metal surface tension is increased to improve ink adhesion, then printing quality improves, but the process becomes more complex
Solution Approach 1:
The anodizing process automatically creates the optimal surface structure for ink adhesion through electrochemical oxidation. The process self-regulates to produce a porous oxide layer with ideal characteristics, eliminating the need for additional surface treatment steps or complex equipment.
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
The method creates colorful patterns on metal surfaces with improved adhesion, resistance to fading, peeling, oil, stains, and corrosion, without using harmful cross-linking agents, thus addressing environmental concerns.
Implementation Method 1
carry out a first anodizing process on a metal substrate to form a first anodic oxide layer on a surface of the metal substrate
Implementation Method 2
form a first anodic oxide layer on a surface of the metal substrate
Implementation Method 3
coat a layer of colorless ink on the first anodic oxide layer on the surface of the metal substrate to form a colorless ink pattern mask
Data Source
AI summary
A method for creating colorful patterns on a metal surface by using colorless ink is revealed. First carry out a first anodizing process on a metal substrate to form a first anodic oxide layer on a surface of the metal substrate. Then coat a layer of colorless ink on the first anodic oxide layer on the surface of the metal substrate to form a colorless ink pattern mask. Later perform a second anodizing process to form a second anodic oxide layer on a part of the metal substrate without being covered with the colorless ink pattern mask. Next remove the colorless ink pattern mask and coat a metal film over the first anodic oxide layer and the second anodic oxide layer to get a colorful pattern on the metal substrate.