Removable UV Curable Dye Sublimation Ink Residual Removal
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Solution Overview
Problem
Existing sublimation printing methods face challenges with residual ink removal, especially on non-flat or soft substrates, as manual scraping is difficult to automate and may not be practical, leading to inefficiencies and increased costs due to the complexity of indirect printing processes.
Innovation Solution
The introduction of removable UV curable dye sublimation inks and printing systems that include a printer head, UV light source for curing, a heating element for sublimation, and a nozzle for solvent jetting to effectively remove residual ink, allowing for easy washing and automation of the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If direct printing is used to eliminate transfer paper, then cost and process complexity are reduced, but residual ink removal becomes difficult especially on soft or non-flat substrates
Solution Approach 1:
The patent changes the chemical parameters of the ink formulation by incorporating soluble components (such as water-soluble polymers, resins, or salts) that allow residual ink to be dissolved and removed by washing with water or solvent, transforming the removal process from mechanical scraping to chemical dissolution
Solution Approach 2:
The patent replaces the mechanical scraping system with a washing system that uses liquid solvents to remove residual ink, enabling automation through spray nozzles or immersion washing stations that can handle soft and non-flat substrates without mechanical contact
2Loss of substance
If manual scraping is used to remove residual ink, then some ink removal is achieved, but automation is difficult and effectiveness varies with substrate type
Solution Approach 1:
The patent replaces mechanical scraping with a chemical washing system using soluble ink components that dissolve in water or solvent, allowing automated spray or immersion washing stations to remove residual ink effectively from any substrate type without mechanical contact
Solution Approach 2:
The patent modifies the ink's solubility parameters by adding soluble polymers, resins, or salts that enable the residual ink to be dissolved by water or solvent, transforming it from a mechanically removable residue to a chemically soluble substance suitable for automated washing
3Ease of operation
If indirect printing with transfer paper is used, then residual ink removal is easier, but cost and process complexity increase
Solution Approach 1:
The patent changes the ink formulation parameters to include soluble components (water-soluble polymers, resins, or salts) that enable residual ink to be washed away with water or solvent, achieving ease of removal similar to indirect printing but with the simplicity of direct printing
Solution Approach 2:
The patent extracts the residual ink removal function from the printing process by making the ink itself soluble, allowing the residual portion to be separately removed through washing without requiring transfer paper or complex mechanical scraping systems
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 automated removal of residual ink from substrates, improving print quality and reducing costs by eliminating the need for transfer paper and manual scraping, while accommodating a wide range of substrate types, including those with surface irregularities.
Implementation Method 1
curing at least some of the ink... The light source can be configured to emit UV radiation of subtype V, subtype A, subtype B, subtype C
Implementation Method 2
heating at least some of the ink to a temperature sufficient to cause sublimation
Data Source
AI summary
Various of the disclosed embodiments concern removable ultraviolet (UV) curable dye sublimation ink to be used in various printing systems and printing methods. In some embodiments, the ink includes a dye component, a UV curable component, and a soluble or solvent-sensitive component. In order to print an image on a substrate, the ink is heated to a temperature sufficient to cause sublimation of at least the dye component. During the sublimation process, the dye is able to permeate the substrate and form a printed image. After the transfer process has been completed, a solvent can be jetted onto the substrate that causes the soluble component to dissolve. The washing process ensures that any residual ink remaining on the surface of the substrate is substantially removed.