Matte Coating Over Digital Foil for Metallic Print Effects
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Solution Overview
Problem
Existing matte finishes in printing are used as ends unto themselves, limiting the creation of new visual effects and are expensive, while matte foil is less available and twice as costly as digital foil, and mechanical embossing is necessary for raised patterns.
Innovation Solution
Applying a matte coating over digital foil and UV-curable polymer coatings to achieve matte metallic and embossed appearances without using matte foil or mechanical embossing, utilizing digital foil and inkjet-printed polymer coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If matte foil is used to create a matte metallic finish, then the desired matte metallic appearance is achieved, but the cost increases significantly and material availability decreases
Solution Approach 1:
The patent uses digital foil as a substitute for matte foil, creating a copy of the desired matte metallic effect through a different material system. The digital foil combined with matte coating reproduces the visual appearance of expensive matte foil at a fraction of the cost, eliminating the need to source scarce matte foil materials.
Solution Approach 2:
The invention creates a composite structure by layering digital foil with a matte coating material. This composite approach combines the metallic appearance properties of digital foil with the light-diffusing properties of matte coating to achieve the desired matte metallic finish without using traditional matte foil.
2Shape
If mechanical embossing is used to create raised patterns, then the embossed appearance is achieved, but additional production steps and machinery are required
Solution Approach 1:
The patent replaces the mechanical embossing process with a chemical/coating-based approach. Instead of using physical rollers and embossing machinery to create raised patterns, the invention uses inkjet-applied clear UV-curable polymer coating that cures to form raised designs, eliminating the need for mechanical embossing equipment and additional production steps.
Solution Approach 2:
The invention changes the method of creating raised patterns from mechanical deformation to chemical curing. By applying UV-curable polymer coating through inkjet printing and then curing it with UV light, the material transitions from liquid to solid, forming raised embossed patterns without mechanical pressure or embossing machinery.
3Manufacturing precision
If traditional embossing machines are used for pattern embossing, then raised patterns are achieved, but production time and complexity increase
Solution Approach 1:
The patent merges the pattern creation and embossing functions into a single integrated process. The inkjet printing system applies the polymer coating in the desired pattern, and the subsequent UV curing simultaneously creates the raised embossed effect, combining what were previously separate operations into one streamlined process that maintains precision while improving productivity.
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
Achieves cost-effective matte metallic and embossed visual effects, eliminating the need for matte foil and mechanical embossing, and enhancing design relief without additional production steps or machinery.
Implementation Method 1
applying a matte coating over raised patterns rendered by an inkjet printer using a clear UV-curable polymer coating
Data Source
AI summary
The invention is directed toward applying a matte finish over other under-layers of applied materials upon a substrate to create a finished article with entirely new visual effects. This invention has applications in the printing arts and significant applications to commercial printing. In one embodiment the matte finish transforms glossy digital foil to a visual effect of a matte appearance. In a second embodiment the matte finish imparts a visual effect of an embossed appearance to patterns and designs.