High Viscosity UV Coating Embossing Stability
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Solution Overview
Problem
Existing methods for coating and embossing in printing processes face issues with the lacquer layer running off before polymerization, leading to reduced functional reliability.
Innovation Solution
A method involving a first fluid with viscosity between 40 and 100 pascal seconds is used for coating and embossing, which is then polymerized using UV radiation, ensuring high dimensional stability of the relief until it hardens, and utilizing a non-circulating system with a chamber doctor blade and specific fluid combinations for enhanced reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a UV lacquer is used for coating and embossing, then the relief can be formed on the printing material, but the lacquer layer runs off before polymerization leading to reduced functional reliability
Solution Approach 1:
The patent changes the viscosity parameter of the coating fluid from typical lacquer viscosity to a higher viscosity range (40-100 pascal seconds). This parameter change prevents the coating material from running off during the embossing process while still allowing it to be applied and embossed effectively. The high viscosity ensures dimensional stability until polymerization occurs.
2Productivity
If a circulatory system with pump and chamber doctor blade is used, then the first fluid can be circulated, but the high viscosity prevents effective circulation
Solution Approach 1:
The patent extracts and removes the circulatory system components (pump, chamber doctor blade) from the process due to their incompatibility with high viscosity fluids. Instead, it uses a simplified system where the high viscosity first fluid is applied directly without circulation, eliminating the problematic components while maintaining functional effectiveness.
3Stability of the object's composition
If the first fluid has high viscosity (40-100 pascal seconds), then the relief has high dimensional stability, but the fluid cannot be circulated in the printing press
Solution Approach 1:
The patent inverts the conventional approach by accepting and utilizing the high viscosity property rather than trying to overcome it. Instead of modifying the fluid to lower viscosity for easier circulation, it reverses the logic and designs a process that works specifically with the high viscosity characteristic, applying the fluid directly without circulation needs.
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 method achieves high dimensional stability and functional reliability by preventing the relief from running off until fully cured, allowing for precise and reliable embossing results.
Implementation Method 1
in a third step the first fluid is polymerized on the printing material by UV radiation in order to harden the relief
Data Source
Figure 1~3
Figure 4~5
AI summary
In a coating and embossing process in a printing press, a substrate (2) is coated with a first fluid (11) in a first step, a relief (4) is embossed into the first fluid (11) on the substrate (2) in a second step using an embossing die, and in a third step the first fluid (11) on the substrate (2) is polymerized by UV irradiation to harden the relief (4). The first fluid (11) is a fluid with a viscosity in the range of 40 to 100 pascal-seconds.