Manufacturing method for printed matter with three-dimensional pattern
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional printing methods using lacquer-containing ink face issues such as prolonged drying times and potential cracking, which hinder the efficient production of three-dimensional patterns on leather or leather-like materials.
Innovation Solution
A manufacturing method involving ultraviolet-curable resin inks, where the surface is treated with varying durations of ultraviolet radiation to form glossy or matte finishes, allowing for rapid production of three-dimensional patterns with a glossy outermost clear layer and a matte or glossy clear layer beneath, on a flexible medium that can mimic animal leather without using real leather.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lacquer-containing ink is used to form three-dimensional patterns, then traditional craftwork appearance is achieved, but drying time is prolonged and cracking occurs
Solution Approach 1:
The patent changes the chemical composition parameters of the ink from traditional lacquer to ultraviolet-curable resin-based ink, and changes the curing mechanism from air-drying to UV light curing. This parameter change eliminates the prolonged drying time and cracking issues while maintaining the ability to form traditional craftwork patterns.
Solution Approach 2:
The patent replaces the natural evaporation-based drying mechanism with a photochemical curing mechanism using ultraviolet light. This substitution transforms the drying process from a time-dependent evaporation process to an immediate photopolymerization process, eliminating drying time and preventing cracking.
2Ease of manufacture
If lacquer-containing ink is used to form three-dimensional patterns, then traditional craftwork appearance is achieved, but cracking occurs under certain drying conditions
Solution Approach 1:
The patent changes the material composition from lacquer to ultraviolet-curable resin, fundamentally altering the curing mechanism. This parameter change eliminates the cracking issue by replacing the problematic air-drying process with UV photopolymerization, which cures the ink immediately upon exposure to ultraviolet light without the stress and cracking associated with traditional drying.
Solution Approach 2:
The patent substitutes the natural evaporation-based drying mechanism with a photochemical curing mechanism. This substitution eliminates the cracking problem by using UV light to initiate rapid polymerization, creating a stable, crack-free finish that maintains the integrity of the three-dimensional pattern.
3Manufacturing precision
If the outermost clear layer is flattened for longer duration, then glossy surface is achieved, but operating time increases
Solution Approach 1:
The patent applies preliminary flattening action to the outermost clear layer before UV curing. By flattening the layer while the ink is still wet and workable, the surface is prepared to achieve a glossy finish. The subsequent UV curing then locks in this flattened, glossy surface immediately, eliminating the need for prolonged flattening time that would otherwise be required.
Solution Approach 2:
The patent uses UV light curing to replace prolonged mechanical flattening processes. Instead of requiring extended time for the surface to naturally settle and dry into a glossy finish, the UV curing mechanism rapidly polymerizes the resin, locking in the desired glossy surface configuration almost immediately after application.
4Productivity
If ultraviolet-curable resin ink is used, then production time is reduced, but additional UV irradiation equipment is required
Solution Approach 1:
The patent introduces UV irradiation equipment to replace the traditional air-drying process. While this adds a new device component, it eliminates the time-consuming evaporation process and enables rapid curing, significantly improving production speed and efficiency despite the added equipment complexity.
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 the rapid and high-quality production of three-dimensional patterns with a glossy surface, reducing production time and maintaining the aesthetic appeal of traditional Inden leather items while ensuring the patterns are uniform and resistant to cracking.
Implementation Method 1
The ink containing the ultraviolet-curable resin, when irradiated with ultraviolet light immediately after landing of the ink on the medium, may be cured before being flattened
Data Source
AI summary
Provided is a manufacturing method for a printed matter including a medium and a three-dimensional pattern printed on a surface of the medium. The three-dimensional pattern has a partly-coated resin portion and further has layers including a colored layer and clear layers formed on the colored layer. The three-dimensional pattern is formed by stacking the layers formed of inks at least containing resin on one another. One of the clear layers formed on an outermost surface of the three-dimensional pattern is flattened for a longer duration than at least one of the other one of the clear layers and the colored layer that are formed below the clear layer on the outermost surface, so that the one of the clear layers on the outermost surface is further flattened than at least one of the other one of the clear layers and the colored layer.