Matrix Roll Printing for Synthetic Image Resolution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional printing techniques fail to achieve high-resolution and dimensional accuracy necessary for synthetic integral images, and embossing followed by ink filling is challenging, especially in large-scale production, due to misalignment and residual ink issues.
Innovation Solution
A method involving a matrix with recesses, where a curable compound is applied, viscosity is increased by partial curing, and excess is removed, allowing precise transfer to a substrate sheet, enhancing adhesive properties and avoiding intermediate surface residuals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional printing techniques (offset printing, flexographic printing, ink-jet printing) are used to form image objects directly on the substrate sheet, then the process is simple and direct, but the resolution and dimensional accuracy are insufficient for synthetic image arrangements
Solution Approach 1:
The patent introduces a matrix roll with recesses as an intermediary element between the curable compound application and the substrate sheet. The matrix roll receives the curable compound in its recesses, allows excessive compound removal, and then transfers the precisely defined compound patterns to the substrate sheet, achieving high resolution without requiring complex direct printing systems
Solution Approach 2:
The patent utilizes the parameter change of the curable compound from liquid state (low viscosity) to solid state (high viscosity after curing). The compound is applied in liquid form to fill recesses, excessive material is removed while in liquid state, and then curing increases viscosity to enable precise transfer and adhesion to the substrate sheet
2Reliability
If embossing cavities in the substrate sheet followed by ink filling is used, then image objects can be formed with proper optical properties, but misalignment and residual ink on intermediate surfaces occur which are detrimental to image quality
Solution Approach 1:
The patent performs the removal of excessive curable compound before the transfer step. By removing excess material while the compound is still in liquid form on the matrix roll surface, the system ensures that only the compound within the recesses remains, preventing residual ink issues during transfer and ensuring proper alignment without requiring post-transfer cleanup
Solution Approach 2:
The patent extracts or removes the excessive curable compound from the matrix roll surface before transfer occurs. This extraction step eliminates the harmful residual ink problem by ensuring that only the precisely contained compound within recesses is transferred to the substrate sheet, leaving no unwanted material on intermediate surfaces
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 high-accuracy, high-resolution printing with improved dimensional tolerances and reduced artefacts, suitable for synthetic image devices and lenticular lenses, allowing for continuous production with precise alignment and minimal residual ink.
Implementation Method 1
a) A curable compound is applied to a matrix roll surface, wherein excessive curable compound is removed from the matrix roll surface; b) The curable compound on the matrix roll surface is cured by means of a UV-irradiation source
Data Source
Figure 1a~1b
Figure 2~3
Figure 4~6
AI summary
The present invention provides a method of producing a product comprising an array of product features (3) arranged on a surface (7) of a substrate sheet (5), and an arrangement for the production of such products. In this method curable compound ( 13) is filled into recesses of a matrix (8), pre-cured and then printed onto the substrate sheet (5), thereby forming printed product features (3). These printed product features (3) and additional product features (2) arranged on the opposed side of the substrate sheet (5) may form image objects and focusing elements, respectively, of a synthetic image device. By way of example a cast cure step can be used to form the additional product features (2). Preferably the production of the product is performed in a continuous roll-to-roll process.