Electromagnetic Ink Transfer Printing for Sharp Conductive Traces
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Solution Overview
Problem
Existing printing technologies face challenges in achieving high contour sharpness and quality for small production runs, particularly when using specific inks like silver-containing inks for conductive traces, which can lead to satellite formation and limited minimum distance between printed lines, and require complex processes and specialized inks.
Innovation Solution
A printing process using an energy-emitting device that emits electromagnetic waves to change the volume and/or position of a printing substance, which includes a high molecular weight binder with a weight average molecular weight of 150,000 to 5,000,000 g/mol, allowing for the transfer of printing substance from a color carrier to a substrate without nozzle clogging and enabling high-quality, cost-effective production of decorations and conductive traces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional printing processes are used for small production runs, then printing plates are required which increase device complexity and setup time, but production flexibility and cost-effectiveness deteriorate
Solution Approach 1:
The invention extracts and eliminates the printing plate component from the printing system, using a digital mask approach instead. The mask is generated electronically and applied during the printing process, removing the need for physical plate creation, storage, and更换 operations, thereby reducing device complexity while maintaining production flexibility
Solution Approach 2:
The invention uses digital masks as virtual copies of the printing pattern instead of physical printing plates. These digital masks can be stored, reproduced, and modified electronically, allowing rapid adaptation to different printing requirements without the complexity of creating and managing physical plates for each design
2Reliability
If digitally controlled printing systems with nozzle-based inkjet technology are used, then printing plates are eliminated, but nozzle clogging occurs leading to reduced reliability
Solution Approach 1:
The invention replaces the mechanical nozzle-based inkjet system with a laser-induced transfer mechanism. Instead of using nozzles to eject ink, the system uses a laser beam to selectively vaporize or decompose the printing substance on the drum surface, transferring it to the substrate. This eliminates the mechanical complexity and clogging issues of nozzle systems while maintaining digital control and reliability
3Productivity
If laser beam printing processes are used to transfer printing ink, then printing plates are eliminated, but very high viscosities are required making the process suitable only for complete carrier replacement
Solution Approach 1:
The invention changes the physical and chemical parameters of the printing substance, specifically using a printing substance with lower viscosity that can be continuously supplied. The laser parameters (wavelength, pulse duration, power) are also optimized to work efficiently with this modified printing substance, enabling continuous operation without requiring complete carrier replacement while maintaining high printing efficiency
4Manufacturing precision
If satellite formation is reduced for high-quality printing, then minimum distance between printed lines is limited, but production speed and area coverage deteriorate
Solution Approach 1:
The invention applies local quality control by using a laser beam with precise spatial control to selectively process only the required printing areas. The laser can be focused to a very small spot size and moved precisely across the substrate, creating sharp contours without satellite formation while maintaining high printing speed through efficient beam scanning and processing
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 process achieves improved print quality with reduced satellite formation, supports small production runs, and allows for customized designs on various substrates like glass, ceramic, metal, and plastic, reducing warehousing costs and setup times while maintaining high adhesion and image sharpness.
Implementation Method 1
mit Hilfe einer energiegabevorrichtung, die im verweilzeitraum energiereiche Strahlung abgibt
Implementation Method 2
das druckpunktgebende material ein change in volume and/or position undergoet
Implementation Method 3
das druckpunktgebende material ein change in volume and/or position undergoet, damit der übertrag zu übertrag bringen wird
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2A~2B
AI summary
The present invention relates to a printing process for transferring a printing substance from an ink carrier onto a print material, according to which the printing substance undergoes a change in volume and/or position due to the effect of an energy-emitting device which emits energy in the form of electromagnetic waves during a process time, the printing substance comprising a high-molecular binder. The present invention furthermore relates to a printing substance for carrying out the process and to the use thereof.