Digital Embossing Ink Layers for Sharp High-Dot Relief
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Solution Overview
Problem
Existing methods for forming embossed patterns with clear varnish films are limited in creating thick and finely detailed convex parts without requiring etching or brushing processes, and existing digital embossing techniques do not allow for the formation of sharper and more defined concave/convex parts.
Innovation Solution
A digital embossing method using active energy ray curable inkjet ink compositions, where two layers of inkjet ink compositions are applied and cured to form a desired embossed surface, with specific viscosity and surface tension conditions, and a time constraint for irradiation, to create fine and sharp convex parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If clear ink is used to form thick clear varnish films, then the film thickness can be increased, but the formation of thick films is limited
Solution Approach 1:
The patent applies parameter changes by controlling the viscosity of the inkjet ink composition within a specific range (10-100 cP at 25°C) and adjusting surface tension parameters (difference between second and first layer surface tension ≥ 4.0 mN/m). These parameter optimizations enable the formation of thick varnish films (5-50 μm) that maintain excellent flow properties and adhesion, resolving the limitation of thick film formation with clear ink.
2Shape
If digital embossing is performed with large dot heights, then the embossed effect is enhanced, but the sharpness and definition of concave/convex parts deteriorates
Solution Approach 1:
The patent achieves both large dot heights (5-50 μm) and sharp concave/convex definitions by optimizing ink composition parameters including viscosity (10-100 cP), surface tension differences between layers (≥ 4.0 mN/m), and using specific resin combinations (polyester resin, acrylic resin, polyurethane resin). These parameter controls enable the ink to flow properly during jetting while maintaining sharp edges after deposition and curing, resolving the contradiction between embossed effect and definition.
Solution Approach 2:
The patent uses composite ink compositions containing multiple resin types (polyester resin, acrylic resin, polyurethane resin) with specific functional properties. This composite material approach allows the ink to exhibit both good flow characteristics for forming large dots and sufficient structural integrity for maintaining sharp edges, enabling simultaneous achievement of high embossed effect and precise pattern definition.
3Shape
If etching or brushing processes are used to form embossed patterns, then the embossed surface can be created, but the process complexity increases
Solution Approach 1:
The patent extracts and eliminates the need for etching and brushing processes by using a specialized inkjet ink composition that self-forms embossed patterns through controlled deposition and curing. The ink's optimized viscosity and surface tension properties allow it to maintain its deposited shape after UV curing, directly creating embossed surfaces without requiring subsequent mechanical processing steps, thus simplifying the overall manufacturing process.
Solution Approach 2:
The patent replaces mechanical etching and brushing processes with a chemical/physical inkjet deposition system. The specialized ink composition, when jetted and cured, directly forms the embossed pattern through controlled material deposition and photopolymerization, substituting complex mechanical processing with a more efficient digital printing approach that achieves the same embossed surface effect.
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 enables the formation of fine digital embossing with sufficiently large dot heights without etching or brushing processes, allowing for the creation of embossed surfaces with clearly defined concave/convex parts using inkjet printing devices.
Implementation Method 1
having a first active energy ray curable inkjet ink composition landed on a substrate surface in the form of liquid droplets of 10.0 pl or greater in volume per droplet, and then irradiated with an active energy ray for pinning, to form a first layer
Data Source
AI summary
A digital embossing creation method includes landing a first active energy ray curable inkjet ink composition on a substrate surface by inkjet printing in the form of liquid droplets of 10.0 pl or greater in volume per droplet, and then irradiating it with an active energy ray for pinning, to form a first layer; and next, landing a second active energy ray curable inkjet ink composition on the first layer by inkjet printing in the form of liquid droplets of 10.0 pl or greater in volume per droplet, and then irradiating it with an active energy ray for pinning, to form a second layer wherein the first and second compositions have a viscosity of 14.0 cps or higher at 25° C., and a value of [(surface tension of the second composition before curing)−(surface tension of the first composition before curing)] is 4.0 mN/m or greater.