Curing Degree Control via Spectroscopic Feedback
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Solution Overview
Problem
Current methods for controlling the curing degree of inks and varnishes on substrates, particularly energy curing inks, are inefficient and unreliable, leading to inconsistent printing quality and increased energy consumption, as they rely on manual adjustments of UV lamp power and machine speed without reliable feedback mechanisms.
Innovation Solution
A method involving cutting a sample from the printed substrate, placing it in a solvent to extract soluble compounds, measuring spectroscopic characteristics, and comparing these values to reference values obtained through an empirical model to adjust the printing process for optimal curing and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual adjustment of UV lamp power and machine speed is used to control curing degree, then printing process can be operated, but curing degree control is unreliable and inconsistent
Solution Approach 1:
The patent implements a feedback mechanism by measuring the curing degree of printed inks/varnishes using spectroscopic methods (UV-Vis, IR, NMR, or mass spectrometry) and using this measurement information to automatically adjust printing process parameters such as UV lamp power, machine speed, and ink application amount, thereby achieving reliable and consistent curing degree control
Solution Approach 2:
The patent replaces manual mechanical adjustment of printing parameters with automated control based on spectroscopic measurement feedback. The system uses measurement information to automatically adjust UV lamp power, machine speed, and other parameters, eliminating reliance on operator experience and manual adjustment
2Reliability
If higher curing degree is achieved to ensure abrasion resistance and prevent migration, then printing quality improves, but energy consumption increases
Solution Approach 1:
The patent implements dynamic adjustment of UV lamp power and machine speed based on real-time or near-real-time spectroscopic measurement of curing degree. This allows the system to apply exactly the right amount of energy needed to achieve the required curing degree (5-95% depending on application), avoiding both under-curing and excessive energy consumption from over-curing
Solution Approach 2:
The patent changes physical and chemical parameters including UV lamp power, machine speed, and ink application amount based on measured curing degree and substrate properties. This optimization ensures that the minimum necessary energy is applied to achieve the required curing degree for preventing migration and ensuring abrasion resistance
3Object-affected harmful factors
If higher curing degree is applied to ensure safety for food packaging, then migration potential decreases, but unnecessary energy is consumed
Solution Approach 1:
The patent applies partial action by determining the precise curing degree needed to reduce migration potential to acceptable levels (converting at least essentially all photoinitiators, monomers, and oligomers) and applying only that necessary amount of UV energy, rather than applying excessive energy to ensure 100% conversion
Solution Approach 2:
The patent replaces conservative over-curing practices with scientifically determined optimal curing levels based on spectroscopic measurement of the ink/varnish composition and measured curing kinetics, achieving the minimum necessary curing degree to prevent migration while minimizing energy consumption
4Manufacturing precision
If multiple parameters are adjusted to optimize curing degree, then printing quality improves, but process complexity increases
Solution Approach 1:
The patent uses spectroscopic measurement feedback to monitor curing degree and automatically adjust multiple process parameters (UV lamp power, machine speed, ink application amount) in a coordinated manner, simplifying the control of complex multi-parameter processes through integrated feedback control
Solution Approach 2:
The patent develops empirical models that can predict optimal printing parameters for different substrates, inks, and varnishes using a unified approach. The spectroscopic measurement method and empirical modeling framework can be applied universally across different printing processes (UV, EB, thermal curing) and material systems
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
This method allows for precise control of curing degree, ensuring high printing quality while minimizing energy consumption and maximizing machine speed, and is universally applicable across various substrates and printing processes.
Implementation Method 1
placing the at least one sample in a solvent, in which at least one of the at least one extractable compound is soluble
Implementation Method 2
quantitatively measuring a spectroscopic characteristic of the solvent extract at at least one wavelength between 190 and 4,000 nm, at which at least one of the at least one extractable compound absorbs or emits radiation
Data Source
AI summary
The present invention relates to a method for controlling the curing degree of at least one at least partially cured ink and/or varnish printed on a substrate, which comprises cutting at least one sample from an area of the printed substrate, placing and incubating it in a solvent, in which at least one of the at least one extractable compound is soluble, and removing it from the solvent to obtain a solvent extract; quantitatively measuring a spectroscopic characteristic of the solvent extract; comparing the measured numeric value of the spectroscopic characteristic with a reference value of the spectroscopic characteristic for the same area of the printed substrate; and outputting a result, wherein the reference value of the spectroscopic characteristic for the same area of the printed substrate has been obtained by the use of an empirical model.