Carrier-Based Multi-Layer Article Manufacturing for Smooth ITM Surfaces
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Solution Overview
Problem
Manufacturing multi-layer articles, particularly large flexible intermediate transfer members (ITMs) with a defect-free ink transfer surface is challenging due to defects such as air bubbles, contaminants, and uneven surface finish, which affect the release layer performance and ink image quality.
Innovation Solution
A method involving the use of a carrier with a defined contact surface to form a curable material layer, which is then cured and peeled off to create a self-supported multi-layer article with a smooth ink transfer surface, minimizing defects and ensuring a consistent finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional multi-layer manufacturing methods are used to create large flexible intermediate transfer members, then the article can be produced, but defects such as air bubbles, contaminants, and uneven surface finish appear on the ink transfer surface
Solution Approach 1:
The patent inverts the traditional manufacturing sequence by first forming the release layer (which becomes the ink transfer surface) on a support layer, then adding subsequent layers. This ensures the ink transfer surface is created first under controlled conditions, preventing defects from later processing steps, while maintaining the required surface finish quality and reducing defect density
Solution Approach 2:
The patent applies preliminary action by pre-forming the release layer with the desired surface characteristics before adding other layers. The support layer is prepared first to provide a stable base, and the release layer is formed with controlled thickness and surface properties before subsequent layers are added, preventing contamination and ensuring consistent surface finish
2Ease of manufacture
If the release layer is formed as the uppermost layer last, then the multi-layer structure is complete, but the topography and surface finish are determined by the underlying layer which may have defects
Solution Approach 1:
The patent inverts the conventional layer assembly approach by forming the release layer first on the support layer, rather than adding it last. This allows the ink transfer surface to be created under optimal conditions with direct control over its topography and finish, while the subsequent layers are added without affecting the already-formed surface quality
Solution Approach 2:
The patent segments the manufacturing process into distinct stages: first forming the support layer, then forming the release layer with specific surface properties, and finally adding subsequent layers. This segmentation allows each layer to be optimized independently, ensuring the ink transfer surface achieves the required precision while maintaining ease of manufacture
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 produces a multi-layer article with a significantly reduced defect density and uniform surface finish, enhancing the quality of ink transfer and image consistency, even in large formats.
Implementation Method 1
said carrier contact surface being wettable by said fluid first curable material
Implementation Method 2
applying said fluid first curable material onto said carrier... at least partially curing said fluid first curable material to form said at least partially cured surface coating
Data Source
AI summary
There is disclosed a method of manufacturing a multi-layered article including a finished outer surface optionally having particular surface properties. The article can be a self-supported strip having a smooth outer surface. The method is, for example, suitable for the preparation of multi-layered articles such as a flexible intermediate transfer member (ITM) for use in an indirect printing system. Uses of such articles are also disclosed.