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 exposed printed images being prone to scratches and smudges, and difficulties in laminating without expensive equipment, including issues like misregistration and air bubbles.
Innovation Solution
A method involving a printed sheet with an image on its rear surface, affixed to an adhesive-coated substrate using a low-tack adhesive, which protects the image from exposure and allows for easy application without industrial laminators, utilizing a squeegee tool and jig for precise alignment and bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the printed image is formed on the front surface of the substrate, then the image is exposed and accessible for viewing, but the image becomes prone to scratches and smudges
Solution Approach 1:
The patent inverts the conventional printing approach by forming the printed image on the rear surface of the substrate instead of the front surface. This inversion allows the image to remain protected from direct contact and environmental damage while still being viewable through the transparent or translucent substrate material, thereby resolving the contradiction between protection and accessibility.
Solution Approach 2:
The patent employs a clear protective sheet or film that covers the front surface of the substrate. This thin film acts as a protective barrier that prevents scratches and smudges on the image while allowing light to pass through, enabling the image to remain viewable. The film can be applied directly over the substrate with the rear-surface print.
2Strength
If conventional lamination processes are used to bond the printed sheet to the substrate, then strong adhesion is achieved, but expensive and large laminators are required, causing misregistration and air bubbles
Solution Approach 1:
The patent changes the parameters of the adhesive by using a low-tack adhesive instead of conventional high-strength laminating adhesives. This low-tack adhesive provides sufficient bonding strength for the application while being applicable through simpler, less expensive equipment. The reduced tackiness also minimizes the risk of misregistration and air bubble formation during the bonding process.
Solution Approach 2:
The patent employs a disposable or single-use adhesive application method that eliminates the need for expensive, complex lamination equipment. The low-tack adhesive can be applied using simple tools or even manual methods, and while the bonding strength may not be as high as industrial lamination, it is sufficient for the intended application, thereby reducing equipment complexity and cost.
3Object-affected harmful factors
If a clear sheet with adhesive is used to bond the printed image to the substrate, then the image is protected, but misregistration and air bubbles occur during lamination
Solution Approach 1:
The patent applies preliminary actions by first forming the printed image on the rear surface of the substrate before applying the clear protective sheet with adhesive. This sequence allows for proper alignment and positioning to be established before the adhesive bonding occurs, reducing the risk of misregistration. The low-tack adhesive also allows for adjustment during the bonding process to correct any alignment issues.
Solution Approach 2:
The low-tack adhesive acts as an intermediary substance that facilitates the bonding between the printed substrate and the clear protective sheet while minimizing problems. Its reduced tackiness allows for easier positioning and adjustment, reducing air bubble formation, and provides sufficient bonding strength to hold the layers together without requiring complex lamination equipment that could cause misregistration.
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 effectively protects the printed image from scratches and smudges by placing it on the rear surface of the substrate, simplifies the lamination process, and reduces costs by eliminating the need for large laminators, while ensuring accurate alignment and bubble-free adhesion.
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.
Data Source
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.