Digital Printed Duct Tape UV Ink Adhesion
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Solution Overview
Problem
Current duct tape printing methods require significant investments in print plates and result in high minimum order quantities, long lead times, and poor print quality, limiting customization and flexibility, especially for small batches or personalized designs.
Innovation Solution
The development of a digitally printed duct tape method using UV-cured ink systems that allows for customized designs without print plates, enabling on-demand printing with high efficiency and cost-effectiveness, and the option to produce custom designs in small batches without a release liner, using techniques like plasma treatment, inkjet printing, and dual-stage UV curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional printing methods (reverse printing or surface printing) are used for duct tape, then the duct tape can be produced with adhesive strength, but the print quality is very poor and ink adhesion is very poor
Solution Approach 1:
The patent applies UV curable ink with specific formulation parameters (resin, monomer, photoinitiator, pigment ratios) and controls curing parameters (UV intensity, exposure time) to achieve both high print quality and strong ink adhesion on the duct tape surface without traditional printing methods
Solution Approach 2:
The patent uses a composite ink system combining UV curable resin, monomer, photoinitiator, and pigment, along with a multi-layer duct tape structure (film, scrim, adhesive layer) to achieve simultaneous improvement in print quality and ink adhesion
2Ease of manufacture
If traditional printing methods are used for duct tape, then production can proceed, but significant investment in print plates is required and minimum order quantities are high
Solution Approach 1:
The patent replaces the mechanical print plate system with a digital printing system that uses UV curable ink and digital file input, eliminating the need for physical print plates and enabling small batch production with high customization flexibility
Solution Approach 2:
The patent changes the production parameter from plate-based traditional printing to digital file-based UV printing, allowing minimum order quantities to be reduced to single units while maintaining production efficiency
3Productivity
If traditional printing methods are used for duct tape, then production can proceed, but lead times are long
Solution Approach 1:
The patent replaces the multi-step traditional printing process (plate preparation, mounting, printing) with a direct digital UV printing process that receives files electronically and prints immediately, reducing lead time while maintaining productivity
Solution Approach 2:
The patent performs preliminary preparation of the duct tape surface (cleaning, priming) before printing and uses rapid UV curing to immediately set the ink, eliminating delays associated with traditional drying or curing methods
4Ease of operation
If duct tape is made thin (5-12 mils) for portability, then it can be easily handled, but it has a tendency to adhere to itself when unrolled
Solution Approach 1:
The patent applies a release coating specifically to the backing layer of the duct tape (the side that contacts itself when rolled), while maintaining the adhesive properties of the front side, thereby preventing self-adhesion without affecting handling ease
Solution Approach 2:
The patent modifies the chemical composition parameters of the backing layer by incorporating release agents (silicone, fluorocarbon, or other release coatings) that change the surface energy and prevent adhesion between tape layers
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 enables fast, inexpensive, and high-quality digital printing of duct tape with customizable designs, allowing for small batch production and personalized applications, such as custom logos or special occasion themes, with improved ink adhesion and reduced self-winding issues, achieving speeds of up to 250 ft/min and flexible production runs.
Implementation Method 1
The methods of the present invention produce a printed duct tape having a UV cured, ink system
Implementation Method 2
using techniques like plasma treatment, inkjet printing, and dual-stage UV curing
Data Source
AI summary
An adhesive tape is provided comprising a duct tape having an adhesive surface and a non-adhesive surface, a white ink printed on the non-adhesive surface of the duct tape, and a colored ink printed on top of the printed white ink. The white ink and the colored ink are digitally printed and UV curable. A self-wound roll of adhesive duct tape having digitally printed ink on the non-adhesive surface of the duct tape is also provided.