Reflection Transfer Layer Order for Faster Offset Printing

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Solution Overview

Problem

The conventional production of reflection transfers is limited by the time required for applying intermediate layers in offset printing, leading to low production rates due to oxidation of offset colorants and adhesion issues, resulting in only 500-800 sheets per hour being processed effectively.

Innovation Solution

Inverting the layer application order by applying a transfer adhesive and optional primer to the base medium first, followed by a colored print image and reflection layer, allowing for pre-drying and storage of sheets before offset printing, which increases productivity and enhances reflection properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If offset printing is used to create colored print images on transfer films, then production rates can be increased to 20,000 sheets per hour, but the total throughput is limited by the time required to apply intermediate layers within a 24-48 hour window, reducing actual production to 500-800 sheets per hour

Engineering Contradiction:

Improveproduction rateVSAvoidtime for applying intermediate layers

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The adhesive layer is applied to the base medium in advance, before the offset printing step, allowing the base medium to be prepared and stored ready for printing. This eliminates the time-critical sequence where intermediate layers must be applied immediately after printing, enabling decoupling of printing and layer application operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The conventional sequence is inverted: instead of applying intermediate layers immediately after offset printing within a tight time window, the adhesive is applied first to the base medium, then offset printing is performed on the pre-prepared sheets. This reverses the dependency relationship and allows independent optimization of each step.

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If intermediate layers are applied too early (less than 24 hours before transfer), then offset colorants are not sufficiently dried and are not wipe-resistant or washing-resistant, but if applied too late (after more than 48 hours), offset colorants oxidize completely and stick to the transfer paper

Engineering Contradiction:

Improvewipe-resistance and washing-resistance of colorantsVSAvoidtime window for applying intermediate layers

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The adhesive layer is applied in advance to the base medium, allowing offset printing to be performed on pre-prepared sheets. This separates the drying time requirement from the printing operation, enabling colorants to dry completely without constraining the printing schedule.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The adhesive layer serves as an intermediary between the base medium and the offset print image, allowing the print image to be applied to a pre-prepared surface. This mediator enables independent timing of adhesive application and printing operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If additional layers are printed on transfer films, then more design options are available, but production rates are further reduced due to additional processing time

Engineering Contradiction:

Improvedesign optionsVSAvoidproduction rate

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The adhesive layer is applied in advance to multiple base medium sheets, creating a stock of pre-prepared substrates ready for printing. This allows offset printing operations to run continuously at high speed without waiting for adhesive application, maintaining high production rates even with multiple printing steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

By preparing adhesive-coated base medium sheets in advance, the offset printing operation can proceed continuously without interruption for adhesive application. This continuous printing process maintains high productivity while accommodating multiple printing steps for enhanced design versatility.

Inventive Principle:

Principle #20Continuity of useful action

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 method enables large-scale, fast, and economical production of reflection transfers with improved reflection properties, achieving production rates of up to 10,000 sheets and allowing for further refinement with additional printing inks, while reducing colorant consumption and changeover times.

Implementation Method 1

applying a transfer adhesive to the base medium

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

applying at least one reflection layer which contains a multiplicity of reflection particles

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS9579874B2Method of producing a reflection transfer for transferring a motif onto a substrate

Publication Date: 2017.02.28 WEBER HOLGER

AI summary

A method of producing a reflection transfer for transferring a motif onto a substrate includes providing an adhesive-repellent base medium, applying a transfer adhesive to the base medium, creating a colored print image by offset printing or digital printing, and applying at least one reflection layer which contains a multiplicity of reflection particles.