Ozoneless UV Curing Web Printing Press
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Solution Overview
Problem
Conventional web printing presses require large spaces and consume significant energy due to their size and the need for thermal drying, while sheet-fed offset presses consume energy and have a high environmental load, and are limited by the narrow wavelength range of LED-UV curing methods.
Innovation Solution
A web printing apparatus using highly reactive UV ink that cures with light irradiation from ozoneless lamps emitting wavelengths between 270 nm to 400 nm, eliminating the need for thermal drying and ozone processing devices, allowing for a downsized and energy-efficient printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal drying is used to fix ink on web, then ink fixation is achieved, but device size and energy consumption increase
Solution Approach 1:
The patent replaces the thermal drying system (mechanical/thermal system) with a light irradiation system (optical system). The light curing device irradiates the web with light in a specific wavelength range to cure the ink, eliminating the need for thermal drying equipment and associated energy consumption while achieving reliable ink fixation.
Solution Approach 2:
The patent changes the curing mechanism from thermal parameters (temperature, hot air flow) to optical parameters (light wavelength, irradiation intensity). By using light in a specific wavelength range that does not generate ozone, the ink is cured through photochemical reaction rather than thermal evaporation, reducing energy consumption and device size.
2Productivity
If thermal drying device is enlarged to handle faster printing speeds, then ink drying reliability improves, but space requirement and energy consumption increase
Solution Approach 1:
The patent replaces the large-scale thermal drying system with a compact light irradiation system. The light curing device can rapidly cure ink without requiring large space or high energy input, enabling high-speed printing while maintaining a compact device footprint and reducing space requirements.
3Reliability
If conventional UV lamp is used for curing, then ink curing is achieved, but ozone is generated causing environmental issues
Solution Approach 1:
The patent changes the light source parameters to emit light in a specific wavelength range that cures the ink without generating ozone. By selecting appropriate wavelengths that do not have sufficient energy to generate ozone but are still effective for curing the ink, the system achieves reliable ink curing while eliminating harmful ozone generation.
Solution Approach 2:
The patent converts the potential harm of UV radiation by carefully selecting the wavelength range. Instead of using broad-spectrum UV that generates ozone, the system uses specific wavelengths that cure the ink effectively without the harmful side effect of ozone generation, turning a potentially harmful process into a beneficial one.
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 enables a compact, energy-saving, and environmentally friendly web printing press that can use a wide range of inks, reducing space and energy consumption while improving printing quality by preventing thermal deformation and expanding ink options.
Implementation Method 1
a fixing device which fixes, on the web, the highly reactive ink/varnish transferred by the transfer device, wherein the fixing device comprises only a light irradiation device which irradiates the web with light in a wavelength range, in which no ozone is generated, to cure the highly reactive ink/varnish on the web without thermal drying of the web
Data Source
AI summary
A web printing apparatus includes a transfer device which transfers highly reactive ink/varnish onto a web, and a fixing device which fixes, on the web, the highly reactive ink/varnish transferred by the transfer device. The fixing device includes only a light irradiation device which irradiates the web with light in the wavelength range, in which no ozone is generated, to cure the highly reactive ink/varnish on the web without thermal drying of the web.