Digital Peel-Off Decal with UV-Cured Lacquer Layer
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Solution Overview
Problem
Current screen-printing processes for creating permanent decals are time-consuming and costly due to the need for multiple color screens, extensive drying times, and post-processing steps, limiting the efficiency and speed of decal production for promotional items like cups and glassware.
Innovation Solution
A digitally produced, water-activated peel-off and slide-on decal method using a base layer of gum-coated paper with a cornstarch and dextrose coating and a lacquer layer, allowing for full-color artwork to be printed in one pass with digital, light-cured inks, which bonds permanently to various surfaces upon drying and heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If screen-printing process with multiple color screens is used, then permanent adhesion and multi-color capability are achieved, but production time and complexity increase significantly
Solution Approach 1:
The patent combines multiple color printing operations into a single digital printing pass, eliminating the need for separate CMYK screens. The digital printing system applies all colors simultaneously in one operation, merging what previously required four separate screen-printing steps into a single unified process.
Solution Approach 2:
The patent replaces the mechanical screen-printing system with a digital printing system. Instead of using physical screens, emulsion coating, and manual printing presses, the invention uses digital inkjet or similar digital printing technology to directly deposit colored inks onto the decal substrate, eliminating complex mechanical apparatus.
2Manufacturing precision
If traditional screen-printing with sequential color layers is used, then complete color coverage is achieved, but production throughput decreases due to extensive drying time
Solution Approach 1:
The patent replaces the slow drying process inherent in traditional screen-printing with a UV curing system. The UV lamps immediately harden the ink layers upon deposition, eliminating the need for extended air-drying periods and enabling continuous high-speed production without compromising color quality.
Solution Approach 2:
The patent utilizes the phase transition of UV-curable inks from liquid to solid state through photopolymerization. When exposed to UV light, the liquid ink rapidly transforms into a solid, cured layer, providing immediate durability and enabling rapid production cycles without prolonged drying times.
3Manufacturing precision
If multiple ink layers are printed sequentially, then full-color artwork is achieved, but production time increases due to drying between layers
Solution Approach 1:
The patent replaces the natural evaporation-based drying process with UV photopolymerization. Instead of waiting for solvents to evaporate between ink layers, the UV curing system instantly hardens each layer as it is printed, eliminating waiting time and enabling continuous multi-color printing operations.
Solution Approach 2:
The patent enables continuous printing of multiple color layers without interruption. The UV curing system operates continuously alongside the digital printing head, instantly curing each layer as it is deposited, thereby maintaining uninterrupted production flow and eliminating idle drying time between color applications.
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 significantly reduces production time from days to hours, eliminates the need for multiple screens and extensive drying, and ensures permanent adhesion to surfaces like ceramic, metal, and glass, while maintaining scratch resistance and durability.
Implementation Method 1
printing a full-color artwork with digital, light-cured printing ink in one printing pass onto the lacquer layer to produce a ready-decal sheet
Implementation Method 2
A digitally printed, water-activated, peel-off and slide-on decal
Data Source
AI summary
A digitally printed, water-activated, peel-off and slide-on permanent transfer decal includes a base layer of gum-coated decal paper comprising a cornstarch and dextrose coating having a thickness of between approximately 10 microns to approximately 30 microns, a layer of lacquer over the cornstarch and dextrose coating of the base layer, and a full-color artwork comprising a digital, UV-LED-cured printing ink printed onto the lacquer layer to form a ready-decal sheet having a decal formed by the ink and the lacquer layer. The lacquer layer has a thickness of between approximately 150 microns and approximately 300 microns, is sandwiched between the cornstarch and dextrose coating and the ink, and is bonded to the ink. The decal is permanently bonded to a surface of an object comprising at least one of ceramic, metal, stainless steel, aluminum, plastic, acrylic, wood, and glass.