Conformable Silicone Elastomer Roller for UV Curing Non-Planar Substrates
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Solution Overview
Problem
Existing printing technologies face challenges in effectively printing on non-planar surfaces, such as the outer layer of corrugated cardboard, due to surface waviness which can result in voids and uneven ink coverage.
Innovation Solution
A printing apparatus utilizing a conformable silicone-based elastomer member transmissive of UV radiation, positioned at a nip with a UV radiation source, ensures uniform ink curing and coverage on non-planar substrates by combining mechanical leveling with simultaneous UV curing, allowing for high-quality image printing on corrugated cardboard surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rigid roller is used for UV curing, then the UV radiation can be effectively delivered, but the ink coverage becomes uneven on non-planar surfaces
Solution Approach 1:
The patent applies a flexible conformable layer made of silicone rubber or fluorocarbon elastomer over the UV radiation source. This flexible shell allows the UV energy to pass through while enabling the layer to conform to non-planar substrate surfaces, thereby achieving both effective UV delivery and adaptability to various surface geometries including corrugated cardboard
Solution Approach 2:
The patent changes the physical state and properties of the conformable member by selecting materials with specific durometer ranges (20-40 shore A for silicone rubber, 15-35 shore A for fluorocarbon elastomer). This parameter adjustment allows the material to be soft enough to conform to non-planar surfaces while remaining sufficiently stable to transmit UV radiation effectively
2Adaptability or versatility
If a soft conformable member is used to adapt to non-planar surfaces, then surface adaptability improves, but UV radiation transmission may be reduced
Solution Approach 1:
The conformable layer is designed as a thin film structure that is soft enough to conform to non-planar surfaces yet thin and compositionally optimized to transmit UV radiation effectively, thus maintaining both surface adaptability and energy transmission
Solution Approach 2:
The patent uses specific elastomeric materials (silicone rubber or fluorocarbon elastomer) that combine the properties of flexibility and UV transmissivity in a single composite material, eliminating the need for separate conformable and transmissive components
3Reliability
If UV radiation is applied to non-planar surfaces, then curing can occur, but voids and uneven coverage result
Solution Approach 1:
The flexible conformable layer conforming to non-planar surfaces ensures uniform contact and pressure distribution across the entire substrate surface, eliminating voids and ensuring both complete UV curing and uniform ink coverage simultaneously
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 solution achieves uniform ink coverage and high-quality image printing on corrugated cardboard by ensuring complete curing and self-stripping of the ink from the roller, overcoming the limitations of surface waviness and ensuring a durable, void-free ink layer.
Implementation Method 1
When exposed to radiation of a predetermined frequency, these co-monomers polymerize and thus bind to any number of types of surfaces
Data Source
AI summary
An apparatus prints and/or fixes ink on a substrate, such as in ink-jet printing with UV-curable inks. A conformable member is positioned to contact an ink-bearing side of the substrate at a nip. The conformable member substantially comprises a silicone-based elastomer having a conformability from about 20 shore A to about 10 shore A. A radiation source directs radiation to the ink-bearing side of the substrate at the nip, the radiation suitable for curing the ink on the substrate. The apparatus is particularly useful for printing onto corrugated cardboard or otherwise non-planar surfaces, since the resulting ink image is impressed uniformly onto the substrate by the conformable member without voids in the ink layer in the recesses of the non-planar surface.