Gloss Control via Selective Clear Ink Deposition
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Solution Overview
Problem
Existing ink jet printing technologies face challenges in achieving consistent gloss control, often resulting in unpredictable output quality, time-consuming adjustments, and potential artifacts like cure banding and ink bleed, due to the need for complex pin and cure systems or multiple pass methods that impact throughput.
Innovation Solution
Implementing a gloss control system that uses clear ink to adjust the surface roughness of printed images by randomly depositing and quickly curing clear ink drops, allowing for selective gloss control without the need for pin and cure systems or multiple passes, using a random-number generator to determine ink drop placement and a UV LED for curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pin and cure systems are used to control gloss levels, then gloss control capability is improved, but device complexity and risk of print artifacts increase
Solution Approach 1:
The patent extracts the gloss control function from the complex pin and cure system by using only clear ink deposition with standard UV curing. This separates the gloss control variable (clear ink coverage) from the complex interaction of pin lamp intensity and ink chemistry, achieving gloss control without the problematic additional hardware
Solution Approach 2:
The patent changes the parameter being controlled from UV lamp intensity (in pin and cure systems) to clear ink coverage percentage. By varying the amount of clear ink applied (0-100% coverage), the system achieves gloss control through a single adjustable parameter rather than complex multi-parameter pin and cure configurations
2Adaptability or versatility
If pin and cure systems are used to control gloss levels, then gloss control capability is improved, but manufacturing precision and output predictability worsen
Solution Approach 1:
The patent implements feedback by measuring the actual gloss units of printed samples and using this data to create media-specific gloss response curves. These curves provide a predictable relationship between clear ink coverage and resulting gloss levels, eliminating the unpredictability of pin and cure systems through data-driven calibration
Solution Approach 2:
The patent transforms the unpredictable chemical interaction process into a predictable parameter-based system by establishing gloss response curves that map clear ink coverage percentages to measured gloss units. This creates a reliable, measurable relationship that improves manufacturing precision
3Illumination intensity
If time-to-lamp is increased to allow ink flow and increase gloss, then gloss level is improved, but productivity decreases
Solution Approach 1:
The patent removes the time delay element from the gloss control process. Instead of extending the time-to-lamp to allow ink flow, it achieves gloss control through immediate clear ink deposition followed by standard curing, maintaining normal printing speed while achieving the desired gloss effect
4Adaptability or versatility
If two-pass spot-gloss printing is used, then spot-gloss capability is improved, but productivity and print quality worsen due to registration errors
Solution Approach 1:
The patent merges the spot-gloss functionality into a single-pass process by using stochastic masking to selectively apply clear ink during the normal printing pass. This combines image printing and gloss control into one operation, eliminating the need for a separate second pass and avoiding registration errors
5Illumination intensity
If UV lamp output is reduced to increase gloss, then gloss level is improved, but cure quality and adhesion worsen
Solution Approach 1:
The patent segments the function of UV lamps from the function of gloss control. The UV lamps maintain their standard intensity for reliable curing, while gloss control is achieved separately through clear ink deposition. This separates the curing function from the gloss-modifying function, allowing both to optimize their respective performance
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 provides a predictable and efficient means of controlling gloss levels, reducing the risk of output defects like gloss banding and improving throughput by allowing for uniform matte or glossy finishes, independent of the substrate's native gloss level, while maintaining a linear and measurable response to clear ink coverage.
Implementation Method 1
a UV LED for curing
Data Source
AI summary
Embodiments of the invention take advantage of the change in gloss caused by overprinting a printed image with clear ink. Embodiments of the invention thus implement gloss control functionality in a printer without the requirements of a pin and cure or other known systems.