System and method for applying an image to a substrate to form a display article

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Solution Overview

Problem

Conventional techniques for printing on metal substrates face challenges such as exposure of the printed image, susceptibility to scratches and smudges, and difficulties in lamination, including misregistration and air bubbles, especially when using expensive industrial laminators.

Innovation Solution

A method involving a printed sheet with an image on its rear surface, which is affixed to an adhesive-coated substrate, using a multi-layer adhesive structure that includes a permanent adhesive for bonding and a low-tack adhesive for repositioning, allowing for easy application without industrial laminators, and a squeegee tool for applying pressure to ensure contact and remove air bubbles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the print is transferred onto the front surface of a plastic substrate with adhesive layer, then the print can be bonded to metal substrate, but the printed image is exposed and susceptible to scratches and smudges

Engineering Contradiction:

Improvebonding capabilityVSAvoidscratch and smudge susceptibility

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent inverts the conventional lamination approach by placing the printed image on the rear surface of the clear substrate instead of the front surface. This inversion protects the printed image from scratches and smudges while maintaining bonding capability through the clear front surface.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent moves the printed image from the traditional two-dimensional front surface to the rear surface dimension, creating a protected three-dimensional structure where the clear substrate acts as a protective barrier between the image and external harmful factors.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If conventional lamination is used to bond printed sheet to metal substrate, then bonding is achieved, but misregistration and air bubbles occur

Engineering Contradiction:

Improvebonding strengthVSAvoidregistration accuracy

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent applies adhesive to the metal substrate before positioning the printed sheet, allowing for adjustment and repositioning during the bonding process. This preliminary adhesive application enables precise registration while avoiding air bubbles through gradual bonding.

Inventive Principle:

Principle #10Preliminary action

3Strength

If industrial laminators are used for lamination, then bonding is achieved, but expensive equipment is required

Engineering Contradiction:

Improvebonding strengthVSAvoidequipment cost

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces expensive industrial laminators with simple, inexpensive tools such as squeegees or credit cards that can be easily obtained. These simple tools suffice for the bonding process, eliminating the need for costly specialized equipment.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent enables the bonding process to be performed by the end user themselves using common household items, without requiring professional equipment or specialized facilities. The process is self-sufficient and does not depend on external industrial resources.

Inventive Principle:

Principle #25Self-service

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 approach protects the printed image from scratches and smudges by keeping it on the rear surface, simplifies the lamination process, and reduces costs by eliminating the need for industrial laminators, while ensuring effective bonding and minimizing air bubbles.

Implementation Method 1

A printed product includes a printed sheet having a front face and a rear face. A printed image is formed along the rear face. The printed product also includes an adhesive coated substrate, such as a ferrous metal substrate, to which the printed sheet is affixed.

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

affixing the rear surface to a top adhesive layer of the adhesive coated substrate by applying pressure to the printed sheet in a direction toward the adhesive coated substrate

Methodology Applied

Scientific EffectPressure application: Compression

Data Source

PatentUS11568771B2System and method for applying an image to a substrate to form a display article

Publication Date: 2023.01.31 TRACER IMAGING LLC

AI summary

A product for displaying an image or object (e.g., printed photo or a print, etc.) according to at least one implementation includes a first sheet having a front face and a rear face. An image or object is formed along the rear face. The product also includes an adhesive coated substrate, such as a ferrous metal substrate, to which the first sheet is adhesively affixed.