UV-Curable Inkjet Bulge Formation for Decorative Plating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing plating methods struggle to achieve uniform gloss on objects, especially when trying to create decorative surfaces with uneven gloss, as they require complex embossing processes that are not suitable for small lot production or varied product designs.
Innovation Solution
A plating method involving a bulge forming process using UV-curable inkjet printing to create distinct surface features, allowing for varying gloss levels and surface roughness, combined with a mask forming process for selective plating, and a heating process to remove internal stress, enabling flexible and decorative plating solutions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hubbly plates are used in embossing processes to create uneven gloss surfaces, then decorative appearance is improved, but device complexity and difficulty of changing embossed shapes increase
Solution Approach 1:
The patent replaces the mechanical embossing system (hubbly plates) with a non-contact inkjet printing system that deposits UV-curable ink to form bulges. This substitution eliminates the need for physical embossing tools, allowing easy programmatic changes to embossed patterns without changing physical equipment, thereby resolving the contradiction between ease of changing shapes and device complexity
Solution Approach 2:
The patent changes the physical state of the ink from liquid to solid through UV curing, creating permanent bulges that mimic embossed effects. By controlling the curing process and ink deposition parameters, various surface profiles can be achieved without mechanical contact, solving the problem of inflexible embossing equipment
2Adaptability or versatility
If hubbly plates are used for embossing to achieve decorative plating, then decorativeness is improved, but adaptability to various product designs decreases
Solution Approach 1:
By replacing mechanical embossing with inkjet-based bulge formation, the system gains digital programmability that enables easy adaptation to different product designs. The same equipment can produce various patterns by simply changing the printing program, greatly improving adaptability while maintaining ease of manufacture
Solution Approach 2:
The inkjet printing system serves multiple functions: it can create different bulge patterns, control surface roughness, and work with various substrates. This multi-functionality allows a single device to handle diverse product designs, resolving the contradiction between adaptability and manufacturing ease
3Ease of manufacture
If UV-curable inkjet printing is used to form bulges, then ease of forming various decorative patterns is improved, but surface roughness control becomes more critical
Solution Approach 1:
The patent applies local quality by creating different surface roughness characteristics in different regions. The inkjet system can deposit ink with controlled thickness and distribution, creating bulges with specific surface properties in targeted areas. This local control allows precise management of surface roughness while maintaining ease of pattern formation
Solution Approach 2:
The patent controls surface roughness by adjusting inkjet printing parameters such as ink droplet size, deposition frequency, and UV curing intensity. By changing these parameters, the surface roughness of bulges can be precisely controlled to achieve desired optical effects while keeping the manufacturing process simple
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
This method allows for easy formation of various decorative patterns and improved decorativeness by creating contrasting gloss levels and surface textures on objects, while ensuring the durability and adhesion of the coating layer, suitable for small lot production and diverse product designs.
Implementation Method 1
a bulge forming process of forming a bulge on an object to be plated by ejecting first ink drops of first UV-curable ink from a first inkjet head such that the ejected first ink drops land on the object
Implementation Method 2
a plating process of plating the object having the bulge formed thereon
Data Source
AI summary
The present invention provides a plating method capable of easily performing various decorative plating processes. The plating method includes a bulge forming process of forming a bulge on an object to be plated by ejecting ink drops of first UV-curable ink from an inkjet head such that the ejected ink drops land on the object, and a plating process of plating the object having the bulge formed thereon, after the bulge forming process. Also, in the bulge forming process, the bulge is formed such that a second surface of the bulge to be plated has surface roughness different from that of a first surface of the object to be plated.