Selective Overcoat Knockouts for Adhesive Bonding
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Solution Overview
Problem
The overcoat material used to protect printed images on media like corrugated cardboard and card stock can prevent adhesives and subsequent printing materials from forming a durable bond, causing issues during processing such as folding, cutting, or gluing, as it forms a durable coating that interferes with adhesive application.
Innovation Solution
A system that uses a fixer material to create 'knockout regions' where the overcoat material does not form a durable coating, allowing for the application of adhesives and additional printing, involving a fixer applicator, print engine, overcoat applicator, and conditioner/cleaner to selectively apply and remove the fixer and overcoat materials, ensuring regions remain bondable and printable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an overcoat material is applied to protect the printed image, then the printed image is protected from scratching and smearing, but the overcoat prevents adhesives and subsequent printing materials from forming a durable bond
Solution Approach 1:
The overcoat layer is segmented into different regions: a first region over the printed image that provides protection, and a second region (knockout region) where the overcoat is removed or inhibited from forming, allowing adhesive bonding. This segmentation resolves the contradiction by providing protection only where needed while maintaining bondability in specific areas.
Solution Approach 2:
The overcoat material is applied with varying properties across different locations. The first region has durable coating properties for protection, while the second region has modified properties (through selective removal or inhibition) that enable adhesive bonding. This local differentiation resolves the contradiction between protection and bondability.
2Reliability
If an overcoat material is applied to protect the printed image, then the printed image is protected from damage, but subsequent printing materials cannot be durably applied
Solution Approach 1:
The overcoat is segmented into a first region protecting the printed image and a second knockout region where the overcoat is removed or inhibited, creating a printable area. This allows subsequent printing materials to be applied durably in the second region while the first region remains protected.
Solution Approach 2:
Different regions of the overcoat have different properties: the first region maintains durable coating characteristics for protection, while the second region has modified characteristics (through selective removal or inhibition) that enable subsequent printing. This local quality differentiation resolves the contradiction.
3Reliability
If a durable coating is formed over the entire printed surface, then maximum protection is achieved, but adhesive and printing applications during processing are interfered with
Solution Approach 1:
The durable coating is segmented into a first region with maximum protection over the printed image and a second region where the coating is removed or inhibited to allow processing operations. This segmentation maintains durability where needed while providing flexibility for processing in specific areas.
Solution Approach 2:
The coating exhibits different properties in different regions: the first region has maximum durability for protection, while the second region has modified properties enabling adhesive bonding and subsequent printing during processing. This local quality variation resolves the contradiction between durability and processing flexibility.
Data Source
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AI summary
Examples described herein include examples methods for generating varnish knockouts that include applying a fixer material to a surface of a print medium (115), selectively applying a print material over the fixer material to form an image, and applying an overcoat material to form a durable coating on areas (215) over the image and a nondurable coating over other areas (220) of the surface.