Photo-Sensitive Printing Layer for Laser Marking Containers
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Solution Overview
Problem
Existing methods for printing on molded containers, such as those using labels or laser engraving, have seen limited commercial adoption due to inefficiencies and lack of versatility in creating decorative and functional markings directly on the container surfaces.
Innovation Solution
A molded article with a photo-sensitive printing layer that changes its visual appearance upon selective irradiation with laser light, allowing for direct printing on the container surface, and a method involving a molding system with a controller to control the injection of a photo-sensitive thermoplastic and marker, enabling the creation of decorative and functional markings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If labels or sleeves are applied to containers for printing, then functional and decorative markings can be provided, but the process complexity and material usage increase
Solution Approach 1:
The printing function is extracted from the label/sleeve system and integrated directly into the container wall through a dedicated printing layer during the molding process. This eliminates the need for separate label application operations while maintaining the ability to provide functional and decorative markings on the container surface.
Solution Approach 2:
The printing layer is merged with the container structure during injection molding, combining the container forming operation with the printing layer integration. This merging eliminates the need for separate label application processes and reduces overall manufacturing complexity despite adding a functional printing capability.
2Ease of operation
If laser engraving is used to mark containers, then direct printing capability is achieved, but the photo-sensitive material and additional processing steps increase complexity
Solution Approach 1:
The photo-sensitive material is incorporated into the printing layer during the initial injection molding process, preparing the container wall for subsequent laser printing. This preliminary action embeds the necessary functional properties before the printing operation, enabling direct laser printing without requiring separate material application steps.
Solution Approach 2:
The photo-sensitive material acts as an intermediary between the laser energy and the container wall, absorbing the laser energy and facilitating the marking process. This intermediary enables direct printing capability by providing a material that responds to laser irradiation, creating the desired visual changes on the container surface.
3Productivity
If a photo-sensitive printing layer is integrated into the molded article, then direct printing efficiency improves, but the manufacturing process complexity increases
Solution Approach 1:
The printing layer formation is merged with the container molding process in a single injection molding operation. This combining of operations allows the printing layer to be created simultaneously with the container wall, improving printing efficiency by eliminating separate printing preparation steps while the molding system handles both container and printing layer formation.
Solution Approach 2:
The injection molding system is designed to perform multiple functions: forming the container wall, incorporating the photo-sensitive material, and creating the printing layer structure. This multi-functionality improves productivity by consolidating multiple operations into a single manufacturing process, though it increases the complexity of the molding system itself.
4Reliability
If multilayer construction is used for barrier properties, then gas and moisture resistance improves, but the material composition and processing complexity increase
Solution Approach 1:
The container wall is constructed using composite materials with a multilayer structure, where the printing layer contains photo-sensitive material and the underlying structure provides barrier properties. This composite construction achieves high gas and moisture resistance while integrating the printing function, though it increases material composition complexity.
Solution Approach 2:
Different regions of the container wall have different material compositions: the printing layer contains photo-sensitive material for marking, while the underlying layers are optimized for barrier properties. This local quality differentiation achieves high reliability for gas and moisture resistance in the barrier layers without compromising the printing capability in the printing layer.
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 efficient and versatile direct printing on containers, improving their aesthetic and informational value while facilitating recycling by using a separable photo-sensitive layer, thus enhancing their recyclability.
Implementation Method 1
a printing layer which is photo-sensitive to laser light of selected properties to change a visual appearance
Data Source
Figure 1
Figure 2A~2D
Figure 3A~3B
AI summary
Disclosed herein, amongst other things, is a container having a printing layer that is printable with exposure to laser light of selected properties.