Marbled Visual Effect Card with UV-Cured Ink Cracks
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Solution Overview
Problem
Existing methods for creating a marbled visual effect on multilayer documents, such as cards to the ISO 7810 standard, are either costly due to solvent evaporation requirements or result in non-durable effects due to external treatment and protection processes.
Innovation Solution
Integrating the formation of cracks during the standard lamination step using a specific ink formulation and thermal-mechanical treatment, which includes 30-50% hexamethylene diacrylate, 20-30% pentaerythritol triacrylate, 10-30% 2-methyl-1-4-(methylthio)pheny-2-morpholino-propan-1-one, and 1-20% colored pigments, and applying UV exposure to create a durable and economical marbled effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ink with solvents is used to create cracks for marbled effect, then random marbled visual effect is achieved, but additional drying time is required increasing manufacturing costs
Solution Approach 1:
The invention changes the chemical parameters of the ink by using solvent-free acrylic polymer ink instead of traditional solvent-based ink. This parameter change eliminates the need for drying time while still allowing crack formation during lamination, thus resolving the contradiction between achieving marbled effect and reducing manufacturing time
Solution Approach 2:
The invention extracts and removes the harmful solvents from the ink formulation, keeping only the acrylic polymer and pigment components. This extraction eliminates the drying time requirement while maintaining the ink's ability to form cracks and produce the desired marbled visual effect
2Reliability
If standard lamination process is used, then document protection is applied, but marbled effect rendering is affected
Solution Approach 1:
The invention performs the crack formation action during the lamination process itself rather than before or after. By timing the crack formation to occur concurrently with lamination, the cracks are created while the document is under controlled thermal and mechanical conditions, ensuring both protection application and precise marbled effect rendering
Solution Approach 2:
The invention merges two previously separate processes - crack formation and lamination - into a single integrated process. The thermal and mechanical conditions of lamination are used to simultaneously apply protection and create the marbled effect through crack formation, resolving the contradiction between protection and rendering quality
3Reliability
If additional roller pass-through step is added to deform card for crack formation, then marbled visual effect is achieved, but manufacturing process complexity increases
Solution Approach 1:
The invention combines the crack formation function with the existing lamination process. The lamination rollers that apply heat and pressure for protection also serve to deform the document and create cracks in the ink layer, eliminating the need for separate roller pass-through equipment and reducing manufacturing process complexity
Solution Approach 2:
The invention makes the lamination process multi-functional by having it simultaneously perform protection application and crack formation. The same lamination equipment serves dual purposes, eliminating the need for additional specialized equipment and simplifying the overall manufacturing process
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 solution achieves a durable and cost-effective marbled visual effect by forming cracks during the standard lamination process, ensuring the effect is integrated into the manufacturing process without additional steps, reducing manufacturing costs and maintaining the effect's durability.
Implementation Method 1
The ink for printing the pattern contains: 30 to 50% hexamethylene diacrylate, 20 to 30% pentaerythritol triacrylate, 10 to 30% 2-methyl-1-4-(methylthio)pheny-2-morpholino-propan-1-one, and 1 to 20% coloured pigments. ultraviolet exposure is carried out simultaneously with the printing of the pattern.
Implementation Method 2
a first treatment at temperature ranging from 110 to 150°C with pressure of 80 to 120N/cm²
Data Source
Figure 1~2
AI summary
This invention concerns a card (1) with a marbled visual effect, said card (1) comprising at least one substrate layer (3) comprising a first and a second side, wherein said substrate layer (3) is covered with a translucent protective layer (7), wherein a pattern (9) cracked by lamination is printed with an UV hardened ink on at least one of the sides of the substrate layer (3) so that the colour located underneath said pattern (9) can be seen through the cracks (11).