UV Inkjet Vision Panels: Single-Pass Layer Registration
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Solution Overview
Problem
Existing inkjet printing methods struggle to achieve the desired opacity and registration of layers in vision control panels, leading to issues like the design being visible from the opposite side, due to limitations in ink interaction and curing processes.
Innovation Solution
The use of digital UV inkjet printing with a novel printhead array and software order, allowing simultaneous printing of base and design layers in a single pass with UV-curable inks, which cure instantly, eliminating the need for air drying or heat processing and reducing layer interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional inkjet printing methods are used to print multiple layers, then the printing process is simple, but the registration precision and opacity of layers cannot be achieved
Solution Approach 1:
The patent changes the fundamental parameter of ink curing from thermal/evaporative to UV photopolymerisation. This allows immediate curing of each layer as it is deposited, enabling precise registration without requiring subsequent drying or heat treatment steps that would cause layer shift and registration errors.
Solution Approach 2:
The patent replaces the mechanical/thermal curing process (drying, heating) with a photopolymerisation process using UV light. This substitution eliminates the need for complex thermal control systems and drying chambers, while achieving immediate layer fixation for precise multi-layer registration.
2Reliability
If multiple layers are printed sequentially with air drying or heat processing, then the inkjet printing is possible, but layer interaction causes loss of opacity and registration
Solution Approach 1:
The patent replaces the time-consuming thermal drying and heat processing steps with immediate UV photopolymerisation curing. Each layer is cured instantly upon UV exposure, eliminating layer interaction during drying and heat treatment, thus maintaining opacity and registration reliability without time loss.
Solution Approach 2:
The patent enables continuous printing and curing of multiple layers without interruption for drying or heat treatment. The UV curing process occurs continuously as each layer is deposited and immediately cured, eliminating idle time and maintaining continuous productive action while ensuring layer integrity.
3Manufacturing precision
If UV curable inkjet inks are used with immediate curing, then layer registration and opacity are improved, but the ink formulation and curing process become more complex
Solution Approach 1:
The patent introduces UV light as an intermediary curing mechanism that activates the photopolymerisation reaction in the ink immediately upon deposition. This intermediary UV curing step enables precise layer registration by fixing each layer instantly, while the UV light source itself serves as a simple, well-understood curing medium.
4Reliability
If conventional inkjet inks are used, then the printing process is straightforward, but the base layer cannot achieve sufficient opacity to prevent design visibility from the opposite side
Solution Approach 1:
The patent changes the ink chemistry from conventional evaporative or thermal curing inks to UV-curable photopolymer inks. This parameter change enables the base layer to achieve sufficient opacity through immediate UV curing, preventing design visibility from the opposite side while maintaining printing process simplicity through automated UV exposure.
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 approach ensures exact registration and opacity, preventing the design from being visible from the opposite side while maintaining high transparency, thus enhancing the quality and efficiency of vision control panels.
Implementation Method 1
all of said plurality of ink layers comprise UV cured ink comprising an agglomeration of overlapping and/or contiguous and/or spaced individual deposits of UV cured ink
Data Source
AI summary
This invention concerns vision control panels and a method of UV inkjet printing vision control panels. A substantially imperforate light permeable material is partially printed with a ‘print pattern’ comprising a base layer and a design layer comprising a design colour layer. The method is limited to digital UV inkjet printing of all the superimposed layers required to make such panels. Optionally, the method uses a novel printhead array with a novel order of ink color supply and/or novel software to enable the required build-up of ink layers, for example of black, optional silver, white, cyan, magenta, yellow and process black colors. Printing is preferably arranged so that the base layer and design color layer are printed in the minimum number of passes of the printhead assembly of the digital UV inkjet printer to achieve the desired effect, preferably in one pass of the printhead assembly.