In-line Primer Printing with UV Pinning and Electron Beam Curing
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Solution Overview
Problem
Existing printing methods face challenges in achieving high-quality images on substrates with uneven surfaces due to inconsistent ink coverage and variable surface characteristics, which can lead to low image clarity, mottling, and increased production costs associated with traditional primer coating processes.
Innovation Solution
A method using radiation curable white inkjet ink compositions with a radiation curable anti-wrinkle agent, pinned with UV light to create a smooth substrate surface, and subsequently exposed to electron beam radiation, allowing for the application of CMYK inkjet ink compositions to produce high-quality prints with improved adhesion and reduced energy costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional primer coating is applied to improve substrate surface characteristics, then adhesion and surface smoothness are improved, but production time and energy consumption increase due to required drying and curing steps
Solution Approach 1:
The patent combines the primer coating application with the image printing process into a single in-line operation. The primer is applied through the same inkjet printing system that applies the image, eliminating the need for separate drying and curing steps between primer application and image printing. This merging of operations reduces production time while maintaining surface smoothness improvements.
Solution Approach 2:
The patent uses radiation-curable primer compositions that can be rapidly cured using UV or electron beam radiation. This changes the curing parameter from traditional thermal drying (which requires extended time and energy) to radiation curing (which occurs almost instantaneously). The primer formulation includes specific resins and photoinitiators that enable this rapid curing transition.
2Manufacturing precision
If a primer coating is applied to achieve uniform ink coverage on uneven surfaces, then image quality is improved, but production costs increase due to additional processing steps
Solution Approach 1:
The patent merges primer application and image printing into a single in-line process using the same inkjet printing system. This eliminates the need for separate primer application equipment, drying infrastructure, and handling operations, thereby reducing capital equipment costs and operational expenses while maintaining image quality improvements on uneven surfaces.
Solution Approach 2:
The inkjet printing system is designed to perform multiple functions: it can apply both the primer coating and the subsequent image-forming ink layers using the same printheads and processing parameters. This multi-functionality eliminates the need for dedicated primer application equipment and reduces overall system complexity and cost.
3Manufacturing precision
If white inkjet ink is pinned with UV light to create smooth surface, then surface roughness is reduced, but energy consumption increases from dual radiation exposure
Solution Approach 1:
The patent combines the pinning radiation and image-curing radiation into a single electron beam exposure step. The electron beam serves dual purposes: it cures the pinned white ink to create the smooth surface, and simultaneously cures the overlying CMYK image layers. This eliminates the need for a separate UV pinning step and a separate image curing step, reducing total energy consumption despite the high energy density of the electron beam.
Solution Approach 2:
The patent uses radiation-induced phase transition of the curable components in the pinned white ink and image inks. The electron beam radiation triggers rapid polymerization of the acrylate or epoxy groups in the ink formulations, transitioning them from liquid to solid state. This phase change occurs instantaneously upon radiation exposure, creating the smooth surface and curing the image in a single energy input event.
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 approach enables the production of sharp, clear, high-quality images on various substrates with low surface roughness, enhancing printing speeds and reducing energy consumption while maintaining excellent adhesion and rub resistance.
Implementation Method 1
pinning with UV light to form a coated substrate with a low surface roughness
Implementation Method 2
exposing the pinned white inkjet ink composition and the CMYK inkjet ink composition simultaneously to electron beam radiation
Data Source
AI summary
A method of forming an image on a substrate that involves applying a radiation curable white inkjet ink composition comprising a radiation curable anti-wrinkle agent onto a surface of the substrate, exposing the radiation curable white inkjet ink composition to UV light having a wavelength of less than 200 nm to pin the radiation curable white inkjet ink composition and form a coated substrate having an arithmetical mean surface roughness value Ra of less than or equal to 2.0 micrometers and an arithmetical mean surface roughness depth Rz of less than or equal to 10.0 micrometers, applying a radiation curable CMYK inkjet ink composition onto the coated substrate, and curing with electron beam radiation.