In-Line Corrugator Primer for UV Inkjet Fan Fold Printing
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Solution Overview
Problem
Existing methods for priming fan fold corrugated materials for UV inkjet printing are inadequate due to the inability to maintain surface quality and uniformity under the harsh conditions of corrugation, including high temperatures and abrasion, which leads to coating flaws and poor print quality.
Innovation Solution
A UV ink jet receptive primer is applied in-line by a corrugator, using a formulation of acrylic colloidal polymer, crosslinking styrenated acrylic emulsion, styrene butadiene polymer, inorganic filler, polymeric wax, and additives, to create a durable surface that withstands corrugator conditions and ensures uniform ink absorption and dot spread.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If analogue coating systems (flexographic station or roller-coater) are used to prime corrugated sheets, then good print quality can be achieved, but the process cannot handle fan fold material due to coating flaws caused by folds
Solution Approach 1:
The primer is applied to the liner board before the corrugation and fan fold process occurs. This preliminary priming ensures that the surface is prepared while still flat and stable, avoiding coating flaws that would result from attempting to prime folded material. The primer is then carried through the corrugation process and remains effective on the final fan fold product.
Solution Approach 2:
The primer acts as an intermediary layer between the liner board and the UV inkjet ink. It provides a consistent, controlled surface that mediates the interaction between the ink and the corrugated substrate, ensuring uniform ink absorption and dot spread regardless of the folds or corrugation structure.
2Reliability
If primer is applied to withstand corrugator conditions (heat, humidity, abrasion), then surface integrity is maintained, but the primer formulation becomes complex
Solution Approach 1:
The primer is formulated as a composite material containing multiple components: acrylic colloidal polymer, crosslinking styrenated acrylic emulsion, styrene butadiene polymer, inorganic filler, and polymeric wax. Each component contributes specific properties to withstand the harsh corrugator conditions - the polymers provide adhesion and flexibility, the inorganic filler provides heat and abrasion resistance, and the wax component provides durability. This composite approach achieves reliable surface integrity through synergistic material properties.
3Productivity
If primer is applied in-line by the corrugator, then continuous production is enabled, but the print station must be repurposed from its original function
Solution Approach 1:
The print station on the corrugator is designed to perform multiple functions: it can apply primer in the same manner it would apply ink, and the same station can later be used for UV inkjet printing. This multi-functionality eliminates the need for separate priming equipment, enabling continuous production while avoiding additional device complexity through a single versatile station.
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 primer enables high-quality UV inkjet printing on continuous folded corrugated materials by maintaining surface integrity and adhesion, resulting in smooth and uniform prints with controlled dot gain.
Implementation Method 1
The primer enhances the quality of the print by controlling the dot spread and the absorption of the ink or components of ink into the paper liner
Implementation Method 2
crosslinking styrenated acrylic emulsion from 10-30%
Data Source
AI summary
A UV ink jet receptive primer is applied by a corrugator to produce a UV ink jet printable, continuous folded, corrugated material, e.g. fan fold. Priming is performed in-line by the corrugator. The primer should withstand the heat, humidity, and abrasion of the corrugator, yielding a surface that can be printed with UV inkjet ink and resulting in a high quality image.