UV-Curable Adhesive Topping Application System
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Solution Overview
Problem
Conventional methods for applying topping materials like glitter to print products result in low resolution due to inefficiencies in adhesive application and excess material removal.
Innovation Solution
A system comprising an adhesive depositing machine, a placement device, a UV energy source, and a topping material removal unit with wheels and vacuum system to precisely apply and cure adhesives, place topping materials, and remove excess materials, utilizing a funnel-shaped receptacle for material dispersion and a cleaning station with rotating wheels for residual removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional silk screening or rolling methods are used to apply adhesive, then the process is simple and fast, but the resolution and precision of topping material application deteriorates
Solution Approach 1:
The patent replaces conventional mechanical adhesive application methods (silk screening, rolling) with a digital printing system that deposits curable adhesive in a pre-determined pattern. This substitution enables precise control over adhesive placement, directly improving the resolution of topping material application while accepting increased system complexity through the adoption of digital printing technology.
Solution Approach 2:
The patent changes the state of adhesive from conventional water-based to UV-curable adhesive. This parameter change allows the adhesive to remain uncured during precise digital deposition and topping material application, then cures uniformly under UV exposure. This enables high-resolution patterned adhesive application that maintains precision throughout the multi-step process.
2Manufacturing precision
If excess glitter is removed by tipping and shaking or vacuuming, then the process is simple, but the resolution and cleanliness of the final product deteriorates
Solution Approach 1:
The patent replaces simple mechanical removal methods (tipping, shaking, vacuuming) with a sophisticated multi-stage removal system. This system uses patterned adhesive deposition to prevent excess material adhesion in the first place, then employs UV curing to secure only desired topping materials, and finally uses controlled vacuum and brush mechanisms to remove any remaining excess. This substitution significantly improves product cleanliness while accepting increased system complexity.
Solution Approach 2:
The patent applies preliminary action by depositing adhesive in a precise pre-determined pattern before applying topping material. This preliminary patterned adhesive layer acts as a template that guides topping material placement and prevents excess material from adhering in unwanted areas. The subsequent UV curing further secures the desired topping materials before final removal of any excess, ensuring high cleanliness without requiring overly complex removal mechanisms.
3Manufacturing precision
If conventional water-based adhesive is used, then the adhesive is easy to handle and self-drying, but the precision and control over adhesive application deteriorates
Solution Approach 1:
The patent changes the chemical composition and curing mechanism of the adhesive from water-based self-drying to UV-curable. This parameter change allows the adhesive to maintain a non-tacky state during digital deposition and topping material application, enabling precise patterned application without premature drying. The UV curing step provides controlled hardening only when needed, improving precision while managing handling characteristics through controlled curing rather than relying on evaporation.
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 system ensures precise application and curing of topping materials, reducing excess material and enhancing the resolution of print products by securely adhering materials to the substrate while removing non-adhered excess, resulting in improved print quality.
Implementation Method 1
a UV energy source configured to apply UV energy to the substrate including the deposited adhesive and the placed topping material to cause curing of the deposited adhesive
Implementation Method 2
a vacuum system mounted above said wheels, said vacuum system configured to suck topping material from said needles and transfer it to said placement device
Data Source
AI summary
Disclosed are systems and methods, including a method that includes depositing a curable adhesive onto a first surface of a substrate in a pre-determined pattern, placing topping material onto the substrate with the deposited adhesive, and applying UV energy to the substrate including the deposited adhesive and the placed topping material to cause curing of the deposited adhesive.