Relief Printing on Curved Surfaces Using Elastic Blanket
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Solution Overview
Problem
Existing methods for printing on curved surfaces, particularly those with a long longitudinal shape, face challenges in achieving high accuracy and multi-color printing due to deformation of elastic blankets and the need for large recess depths in intaglio printing master plates, leading to increased costs and complexity.
Innovation Solution
A method using a relief printing master plate with a protrusion portion of 0.1-50 μm height and a rubber or rubbery roll-like elastic blanket with specific hardness and surface roughness, applied under constant pressure and rotated to transfer ink accurately onto curved surfaces, ensuring high printing accuracy and adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If an intaglio printing master plate with deep recess portions is used to retain ink volume, then ink retention is improved, but the elastic blanket surface deforms largely and printing accuracy deteriorates
Solution Approach 1:
The invention inverts the conventional intaglio approach by using a relief printing master plate where ink is applied to protrusion portions rather than recess portions. This inversion eliminates the need for deep recesses while maintaining ink retention through controlled application to elevated surfaces, thereby preventing elastic blanket deformation and preserving printing accuracy on curved surfaces
Solution Approach 2:
The invention changes the critical parameter of master plate topography from deep recesses (intaglio) to shallow protrusions (relief). By controlling the height of protrusion portions within 0.1-50 μm and using relief geometry, the system achieves adequate ink retention without causing excessive elastic blanket deformation, thus resolving the contradiction between ink volume retention and printing accuracy
2Adaptability or versatility
If the elastic blanket is made soft enough to adapt to the difference between protrusion and recess portions, then adaptability to curved surfaces is improved, but printing accuracy deteriorates due to excessive deformation
Solution Approach 1:
By inverting from intaglio to relief printing, the system eliminates deep recesses that cause excessive blanket deformation. The relief configuration with shallow protrusions (0.1-50 μm) allows the elastic blanket to conform to curved surfaces through minimal, controlled deformation, maintaining both adaptability and printing accuracy simultaneously
3Manufacturing precision
If a flat relief printing master plate is used, then the difference in height is reduced and a slightly hard blanket can be used, but the elastic blanket must still deform to contact the curved surface
Solution Approach 1:
The invention applies curvature to the elastic blanket itself, forming it into a roll-like structure with a curved surface that corresponds to the to-be-printed curved surface. This curvature matching allows the blanket to contact the curved surface without excessive deformation while maintaining printing accuracy, and the relief master plate ensures proper ink transfer to the curved blanket surface
4Quantity of substance
If an intaglio plate with large recess depth is used, then ink volume is retained, but fine dot printing accuracy deteriorates extremely
Solution Approach 1:
By inverting from intaglio to relief printing, the system eliminates deep recesses that cause excessive ink volume and deformation. The relief configuration with controlled protrusion heights (0.1-50 μm) allows precise ink application to protrusion portions, enabling accurate fine dot printing while maintaining adequate ink retention through controlled geometry rather than depth
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 accurate and cost-effective printing on curved surfaces with improved ink transfer and reduced deformation, suitable for mass production and complex shapes like car parts, while simplifying the specification determination of elastic blankets.
Implementation Method 1
pressing a rubber or rubbery roll-like elastic blanket onto the relief printing master plate disposed in a fixed position and supplied with the printing ink while applying constant pressure to the roll-like elastic blanket and smoothly rotating the roll-like elastic blanket, so as to transfer the printing ink to an outer circumferential surface of the roll-like elastic blanket
Data Source
AI summary
A method for printing on a curved surface and a printed curved surface body using the method. The method includes the steps of: applying printing ink having a viscosity of 5-500 PaS, preferably 5-250 PaS, to a protrusion portion of a relief printing master plate 3 which is a flat plate with the protrusion portion 0.1-50 μm high, preferably 0.1-25 μm high in height h; pressing a rubber or rubbery roll-like elastic blanket 2 having an elastic portion whose thickness T has a relation of 2H≦T≦8H with respect to a level difference H of a to-be-printed curved surface body 10 and which has a hardness (JIS A-scale) of 3-40, preferably 3-20, onto the relief printing master plate 3 supplied with the printing ink while applying constant pressure to the roll-like elastic blanket 2 and smoothly rotating the roll-like elastic blanket 2, so as to transfer the printing ink to an outer circumferential surface of the roll-like elastic blanket 2; and moving the roll-like elastic blanket 2 having the printing ink transferred thereto, and bringing the roll-like elastic blanket 2 into rotational pressure contact with a surface of the to-be-printed curved surface body 10 so as to perform printing thereon.