3D-Microoptic Packaging via Filmless Casting and Micro-Lenses
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Solution Overview
Problem
Current 3D-microoptic films for packaging systems face issues such as requiring transparent substrates for image visibility, loss of flexibility due to lenticular designs with lenses larger than 1 mm, and unpleasant surface textures, which detract from consumer appeal.
Innovation Solution
A method involving a substrate with images printed on one surface, a transparent varnish layer applied, and micro-lenses formed on the varnish layer's outer surface using a filmless casting process with a flexographic casting plate, allowing for flexible and appealing packaging systems with 3D-microoptic effects on both transparent and non-transparent substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If lenticular designs with lenses larger than 1 mm are used, then 3D-microoptic effects are achieved, but flexibility of the packaging system decreases
Solution Approach 1:
The patent changes the size parameter of the lenses from large (1 mm or more) to micro-sized (smaller than 1 mm). This parameter change allows the packaging system to maintain flexibility while still achieving the desired 3D-microoptic effects, resolving the contradiction between optical effectiveness and mechanical flexibility.
2Loss of information
If transparent substrates are used for image visibility, then images are apparent, but the substrate restricts material selection
Solution Approach 1:
The patent moves the image layer and lens layer to different dimensional positions on the packaging structure. By placing images on one surface and lenses on the opposite surface, the system achieves image visibility without requiring the substrate itself to be transparent, thereby expanding material selection to include opaque substrates.
3Area of stationary object
If continuous relief features are used, then surface coverage is improved, but the moire magnifier effect cannot be achieved
Solution Approach 1:
The patent segments the continuous relief features into discrete, separated lens elements. This segmentation allows each lens to function independently in creating the moire magnifier effect while collectively providing comprehensive surface coverage, resolving the contradiction between continuous coverage and optical effect precision.
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
Enables the creation of flexible packaging systems with 3D-microoptic images that maintain flexibility and provide a smooth surface, enhancing consumer appeal while achieving the moire magnifier effect without compromising substrate properties.
Implementation Method 1
forming a plurality of relief features on the outer surface of the varnish layer, wherein the relief features are micro-lenses, characterized in that the relief features on the varnish layer are formed by a filmless casting process using a flexographic casting plate
Implementation Method 2
The resulting 3D micro-optic image is caused by a printed substrate with a regular pattern of micro-images superimposed with a varnish layer with circular micro-lenses
Implementation Method 3
Especially, in the field of packaging systems, 3D-microoptic decoration techniques are of great interest, since they provide a high impact on the first impression of a product and serve as an eye-catcher with high holding power for consumers to stop at a product
Data Source
Figure 1
Figure 2a~2d
Figure 3a~3c
AI summary
The invention relates to a method for printing 3D-microoptic images on packaging systems in an inline process comprising providing a substrate, printing a plurality of images on at least part of the first major surface of the substrate, applying a transparent varnish layer on the printed first major surface of the substrate, and forming a plurality of relief features on the outer surface of the varnish layer, wherein the relief-features are micro-lenses.