UV-Curable Gellant Composition for Raised Print Embossing
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Solution Overview
Problem
Current raised print processes are limited in achieving heights above 30 micrometers, lack compatibility with various colors, and require intermediate UV curing, making them inefficient and complex for in-line production of both flat and raised prints on xerographic images.
Innovation Solution
A process using an ultraviolet curable phase change gellant composition comprising radiation curable monomers, photoinitiators, and gellants, which can be jetted at elevated temperatures and cured without intermediate UV pinning, allowing for the creation of raised images up to 60 micrometers in height over xerographic images in an in-line process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional thermographic processes are used to create raised print, then the process can produce embossed images, but fine lines are difficult to emboss and the process is incompatible with many colors
Solution Approach 1:
The patent changes the physical and chemical parameters of the embossing material by using UV-curable compositions with controlled viscosity and gelation properties. This allows the material to be deposited in liquid form that can capture fine details, then cured to create the raised effect, enabling both fine line quality and color compatibility
Solution Approach 2:
The patent replaces the traditional mechanical thermographic embossing system with a digital printing system that uses UV-curable inkjet technology. This substitution enables precise deposition of material for fine lines while maintaining compatibility with full-color printing processes
2Productivity
If current ink jet techniques are used for raised print, then the process can be simplified, but the printing speed is slow and not in-line with the digital printer
Solution Approach 1:
The patent merges the flat print and raised print processes into a single in-line operation. The UV-curable composition is deposited directly over the freshly printed image while the substrate is still on the conveyor, allowing both flat and raised elements to be created in one continuous pass without slowing production
Solution Approach 2:
The patent performs the raised print deposition immediately after the flat print is applied, while the substrate is still in position on the conveyor belt. This preliminary action allows the raised material to be applied and cured before the substrate leaves the printing zone, maintaining high-speed in-line production
3Productivity
If intermediate UV curing is required during the raised print process, then the curing can be controlled, but the process complexity increases and efficiency decreases
Solution Approach 1:
The patent uses a UV-curable composition that can be cured in a single continuous UV irradiation step after deposition. The composition is designed to remain stable during deposition and only cure when exposed to UV light, eliminating the need for intermediate curing steps and allowing continuous production flow
Solution Approach 2:
The patent extracts the intermediate UV curing step from the traditional multi-step process. By using a composition that cures completely in a final UV treatment, the patent removes the complex intermediate pinning and re-deposition steps, simplifying the overall process while maintaining control
4Manufacturing precision
If thermographic powder is applied and removed from non-dimensional ink areas, then the raised print can be created, but the process becomes complex and time-consuming
Solution Approach 1:
The UV-curable composition is deposited selectively by the inkjet system only in the areas where raised print is desired, based on the digital image data. The material itself defines the raised areas through selective deposition and UV curing, eliminating the need for separate powder application and removal steps to create definition
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 robust, efficient, and high-speed production of raised prints with improved color compatibility and reduced complexity by eliminating the need for intermediate UV curing, achieving heights of 40 to 60 micrometers without penetration into the substrate.
Implementation Method 1
an ultraviolet curable phase change gellant composition comprising a radiation curable monomer or prepolymer, a photoinitiator
Implementation Method 2
ultraviolet curable phase change gellant composition
Data Source
AI summary
A process including providing a substantially flat printed image on a substrate; disposing a curable gellant composition onto the printed image in registration with the printed image, successively depositing additional amounts of the gellant composition to create a raised image in registration with the printed image; and curing the deposited raised image. A process including providing a printed image on a substrate; disposing a curable non-gellant composition onto the printed image in registration with the printed image; and disposing a curable gellant composition onto the printed image in registration with the printed image; to create a raised image in registration with the printed image; and curing the deposited raised image. An ultraviolet curable phase change gellant composition including a radiation curable monomer or prepolymer, a photoinitiator, a silicone polymer or pre-polymer, and a gellant.