UV Varnish Embossing for Matt-Gloss Effects in Offset Printing
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Solution Overview
Problem
Existing methods for coating and embossing printing materials in inline processes are limited in achieving high-quality matt/gloss effects and haptic enhancements, particularly in offset printing, due to constraints in layer thickness and embossing precision.
Innovation Solution
The method involves applying an ultraviolet (UV) varnish to the printing material, embossing the non-polymerized lacquer layer, and then polymerizing it using UV radiation, allowing for thicker layers and improved embossing effects, which can be combined with multicolor printing and additional coatings in an inline processing machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional coating methods are used, then the coating process is simple, but the layer thickness is limited and embossing precision is insufficient
Solution Approach 1:
The patent applies a coating layer to the printing material before embossing, allowing the embossing process to work on a prepared surface. This preliminary coating enables better embossing precision by providing an optimal surface for the embossing plate to contact and deform, while the coating itself can be applied using conventional methods to maintain process simplicity.
Solution Approach 2:
The patent changes the physical and chemical parameters of the coating material, specifically using UV-sensitive lacquer that undergoes polymerization. By controlling the polymerization state (applying before embossing, then curing after), the system achieves superior embossing precision through parameter control rather than complex mechanical processes.
2Manufacturing precision
If thicker coating layers are applied, then matt/gloss effects and haptic quality improve, but the coating process becomes more complex
Solution Approach 1:
The patent utilizes UV-sensitive lacquer that undergoes polymerization when exposed to UV radiation. By applying the coating in a non-polymerized state and then curing it after embossing, the system achieves thicker effective layers with improved matt/gloss effects and haptic quality. The parameter change from non-polymerized to polymerized state enables better embossing and final surface quality without requiring complex multi-step coating processes.
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 enables the production of enhanced matt/gloss effects and improved haptics by allowing higher layer thicknesses and precise embossing, upgrading the printing material's quality and functionality.
Implementation Method 1
the embossed lacquer layer is then polymerized. For polymerization, the embossed lacquer layer is temporarily exposed to ultraviolet (UV) radiation/drying
Data Source
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AI summary
The method involves guiding a print substrate which coats a surface of the print substrate with a lacquer coat. A gap (12) comprises a paint guiding cylinder (2) with a dosing device (9) and an impression cylinder (5). The print substrate is coated with ultraviolet paint in the gap, where unpolymerized lacquer coat is located on the surface of the print substrate which is embossed in another gap (13). An independent claim is also included for a device for coating and embossing a print substrate in a processing machine.