UV-Cured Printed Release Foil for Single-Pass Coating
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Solution Overview
Problem
The production of release films is complex due to separate work steps for printing and applying a release coating, necessitating an improved process.
Innovation Solution
A release film comprising a carrier layer, a printed image, and a release coating, where the printed image is partially arranged between the carrier layer and the release coating, with both the ink and release coating being radically cured by UV radiation, allowing simultaneous printing and application in a single operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If printing and release coating application are performed in separate work steps, then manufacturing precision can be maintained, but production time increases and productivity decreases
Solution Approach 1:
The patent combines the printing process and release coating application process into a single integrated work step. The printing unit and coating unit are arranged adjacently on the same production line, allowing both operations to be performed simultaneously on the carrier layer in one pass, thereby eliminating the need for separate processing steps and reducing overall production time.
Solution Approach 2:
The printing operation is performed before the release coating application within the same work step. By pre-printing the carrier layer with the desired pattern and then immediately applying the release coating over it in sequence, the patent ensures that the printed features are preserved while achieving the release properties, all within a single integrated process.
2Productivity
If printing is performed before applying release coating in separate steps, then adhesion can be controlled, but production complexity and time increase
Solution Approach 1:
The patent merges the printing and coating operations into a single integrated unit where both functions operate simultaneously on the carrier layer. This integration maintains precise control over the adhesion between the printed layer and release coating while eliminating the complexity of coordinating separate processing steps.
3Loss of time
If conventional printing and coating methods are used separately, then process control is simplified, but production time doubles
Solution Approach 1:
The patent integrates two previously separate processes (printing and release coating application) into a single combined work step. The printing unit and coating unit are positioned adjacently on the production line, allowing both operations to occur in one pass through the system, thereby halving the production time while maintaining manageable process complexity through modular design.
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 significantly reduces production time, potentially halving it, enhances precision, and improves adhesion between the printed image and release coating, while eliminating undesirable effects from conventional methods.
Implementation Method 1
the printed image comprises at least one ink radically cured by UV radiation, and wherein the release coating comprises a polysiloxane radically cured by UV radiation
Data Source
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Figure 3~4
Figure 5A~5B
AI summary
The invention relates to a release foil comprising a substrate layer, a printed image and a release coating, wherein the the printed image is arranged at least partially between the substrate layer and the release coating, wherein the printed image includes at least one dye that is cured by UV radiation, and wherein the release coating includes a polysiloxane that is cured by UV radiation.