UV-Curable Ink Printing with Dual-Energy Irradiation for Matte Scratch Resistance

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Solution Overview

Problem

Conventional printing technologies face challenges in producing matte images with high scratch resistance, especially when printing with high ink duty, as the surface becomes flat and lacks glossiness, and using clear ink can compromise scratch resistance and increase costs.

Innovation Solution

A printing apparatus and method utilizing a head unit that ejects yellow UV curable-type ink and an irradiating section with a controller that adjusts UV light energy, irradiating with lower energy initially to create a concavo-convex surface and then higher energy to cure the image, eliminating the need for clear ink and achieving high scratch resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If high ink duty is used to print color image, then ink coverage is improved, but surface glossiness increases and matte effect is lost

Engineering Contradiction:

Improveink coverageVSAvoidsurface glossiness

Core Design Contradiction:

Quantity of substanceVSShape

Solution Approach 1:

The ink ejection process is segmented into multiple passes: first ejecting color ink to form the base image, then selectively ejecting clear ink droplets in subsequent passes to create localized concavo-convex structures that provide matte effect while preserving overall high ink coverage

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Clear ink droplets are selectively ejected only in specific regions or at specific densities to create localized surface irregularities. This allows different areas of the image to have different surface properties - some areas maintain smooth glossy finish while others develop matte texture, achieving overall matte effect without compromising total ink coverage

Inventive Principle:

Principle #3Local quality

2Shape

If clear ink droplets are ejected sparsely on color image to create matte effect, then surface concavo-convex structure is improved, but scratch resistance deteriorates

Engineering Contradiction:

Improvesurface concavo-convex structureVSAvoidscratch resistance

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The color ink is first ejected and partially cured to form a stable base layer with adequate scratch resistance. Then clear ink droplets are selectively added in subsequent passes to create surface texture. This preliminary establishment of the color ink layer ensures that the foundation structure maintains strength while the added clear ink droplets provide the desired matte effect

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Clear ink droplets are ejected at controlled, sparse densities rather than uniformly across the entire image. This partial application creates enough surface irregularities to achieve matte effect while avoiding excessive clear ink accumulation that would compromise scratch resistance. The sparse distribution ensures the color ink layer remains the primary load-bearing structure

Inventive Principle:

Principle #16Partial or excessive action

3Shape

If clear ink is used to create matte image, then glossiness is improved, but manufacturing cost increases

Engineering Contradiction:

Improveglossiness controlVSAvoidmanufacturing cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The patent extracts the essential function of clear ink (creating surface irregularities for matte effect) and implements it through a more economical approach: using selectively ejected clear ink droplets in controlled patterns rather than applying uniform clear ink layers. This reduces clear ink consumption while maintaining the matte effect, thereby lowering manufacturing costs

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the application parameters of clear ink from uniform continuous coverage to selective sparse droplet ejection. By controlling the density, size, and distribution of clear ink droplets, the system achieves effective matte effect with reduced material consumption, lowering manufacturing costs while maintaining glossiness control capability

Inventive Principle:

Principle #35Parameter changes

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 allows for the production of matte images with high scratch resistance and controlled glossiness without using clear ink, reducing costs and improving image durability.

Implementation Method 1

the type using a UV curable-type ink that cures under the irradiation of a UV light

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS9022545B2Printing apparatus for irradiating UV light on ink ejected on medium and printing method for irradiating UV light on ink ejected on medium

Publication Date: 2015.05.05 SEIKO EPSON CORP

AI summary

A printing apparatus having a head unit that ejects a yellow UV curable-type ink onto a medium, an irradiating section that irradiates the UV light, and a controller that works as follows: when the first mode is set, control is carried out so that, after the UV light with the first energy is irradiated on the UV curable-type ink ejected onto each unit area of the medium, the UV light with the second energy higher than the first energy is irradiated; when the second mode is set for printing an image with a glossiness higher than that of the image printed according to the first mode, control is carried out so that the UV light with an energy higher than that of the first energy is irradiated on the UV curable-type ink ejected on unit area of the medium.