UV Ink Cure Degree Monitoring via Reflectance
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Solution Overview
Problem
Conventional methods for determining the degree of cure of ultraviolet (UV) sensitive inks in the printing industry are typically offline, leading to wastefulness in time and materials, and lack real-time monitoring capabilities, which can cause delays and inefficiencies.
Innovation Solution
A system that applies UV inks to a substrate, exposes them to UV light, and uses a UV reflectance device to determine the degree of cure based on reflectance values, allowing for real-time adjustment of curing attributes such as wavelength, intensity, and exposure time to achieve a desired level of cure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional offline methods (MEK rub test) are used to determine degree of cure, then measurement precision can be achieved, but loss of time and loss of materials increase significantly
Solution Approach 1:
The patent replaces the mechanical MEK rub test with an optical measurement system that uses UV light sources and sensors to detect reflectance changes. This substitution eliminates the need for physical material consumption and manual testing procedures, achieving real-time, non-contact measurement of cure degree while maintaining measurement accuracy.
Solution Approach 2:
The patent introduces UV reflectance as an intermediary parameter to indirectly measure the degree of cure. Instead of directly testing adhesion through MEK rubs, the system measures changes in UV light reflectance from the cured surface, which correlates with cure status. This intermediary measurement enables continuous monitoring without consuming materials or time.
2Measurement precision
If conventional offline methods are used to determine degree of cure, then measurement precision can be achieved, but loss of materials increases significantly
Solution Approach 1:
The patent replaces the mechanical MEK rub test with an optical measurement system that uses UV light sources and sensors to detect reflectance changes. This substitution eliminates the need for physical material consumption and manual testing procedures, achieving real-time, non-contact measurement of cure degree while maintaining measurement accuracy.
Solution Approach 2:
The cured surface itself serves as the measurement medium by reflecting UV light in a characteristic pattern that indicates cure status. The system uses the surface's own optical properties to provide self-diagnosis of cure degree without requiring external test materials or consumables.
3Productivity
If real-time monitoring is implemented using UV reflectance measurement, then productivity increases, but device complexity increases
Solution Approach 1:
The patent integrates the UV reflectance measurement system into the existing printing system, allowing the same UV light sources to serve dual purposes: curing the ink and simultaneously providing illumination for reflectance measurement. This multi-functionality approach enables real-time monitoring without adding separate dedicated measurement equipment, thereby limiting the increase in device complexity.
4Manufacturing precision
If real-time monitoring and adjustment of curing process is implemented, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The patent implements a feedback control system where UV reflectance measurements are continuously monitored during the curing process, and the data is fed back to adjust curing parameters in real-time. This closed-loop feedback enables precise control of cure degree, ensuring consistent quality while allowing dynamic adaptation to varying conditions without requiring overly complex hardware.
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 real-time monitoring and adjustment of the curing process, reducing waste and improving image quality by preventing defects like pin-holes and image offset, while allowing for on-demand modification of the curing process to achieve uniformity across multiple printing systems.
Implementation Method 1
UV curable inks are widely used in the printing industry for a variety of applications from varnishing, packaging, food and pharmaceutical labeling, etc. These inks cure and harden when exposed to UV radiation
Implementation Method 2
determining a reflectance value associated with the cured image
Data Source
AI summary
An approach is provided for determining a degree of curing of one or more ultraviolet sensitive inks. The approach involves causing, causing, at least in part, one or more ultraviolet inks to be applied to a substrate to form an image. The approach also involves causing, at least in part, the image to be exposed to ultraviolet light produced by one or more ultraviolet light sources to cause, at least in part, the one or more ultraviolet inks to be cured to form a cured image. The approach additionally involves determining a reflectance value of the cured image. The approach further involves determining a degree of cure of the cured image based, at least in part, on the reflectance value. The approach may be used to alter the degree of curing of another image applied to a substrate.