UVLED Inkjet Printer Two-Stage Curing for Print Quality
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Solution Overview
Problem
Conventional inkjet printers using ultraviolet curable ink face issues with print quality due to uncured ink droplets being cured in a beading or mixed state, leading to optical fringes and poor print quality, and require a balance between print quality and printing speed.
Innovation Solution
An inkjet printer with a mode switching capability between two-stage and single-stage curing, using UVLEDs for controlled ultraviolet light emission, allowing for temporary curing of ink droplets to a gel state for leveling and final curing, and adjusting light quantity and moving speed to optimize print quality and speed based on application needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If UV ink droplets are completely cured immediately after deposition, then curing speed is improved, but ink droplets become beaded and print quality deteriorates
Solution Approach 1:
The curing process is divided into two distinct stages: a first curing stage that partially cures the UV ink to improve leveling without causing beading, and a second curing stage that completely cures the ink for final fixation. This segmentation allows each stage to optimize for its specific function, resolving the contradiction between curing speed and print quality.
Solution Approach 2:
The first curing stage performs a preliminary curing action that partially cures the UV ink immediately after deposition. This preliminary action levels the ink droplets before complete curing occurs, preventing beading while preparing the ink for final curing in the second stage.
2Productivity
If UV ink droplets are not cured between passes, then printing speed is improved, but ink droplets mix and bleed leading to poor print quality
Solution Approach 1:
The curing process is segmented into two stages where the first stage provides partial curing between passes. This partial curing is sufficient to prevent ink mixing and bleeding while maintaining printing speed, as complete curing is not required between passes but rather a gel state that prevents diffusion.
Solution Approach 2:
The curing parameters are changed between the two stages: the first stage uses lower energy or shorter duration UV irradiation to achieve partial curing and gel state, while the second stage uses higher energy or longer duration for complete curing. This parameter change allows optimization for both speed and quality.
3Manufacturing precision
If two-stage curing is implemented, then print quality is improved, but device complexity increases
Solution Approach 1:
A single UV irradiation device is designed to perform both curing stages by adjusting operational parameters such as irradiation intensity, duration, or wavelength. This multi-functionality allows the same hardware to achieve both partial and complete curing, reducing device complexity while maintaining print quality improvement.
4Weight of moving object
If UVLEDs are used for ultraviolet light emission, then device size and weight are reduced, but curing control precision must be maintained
Solution Approach 1:
The UVLED system controls curing precision by changing operational parameters such as drive current, pulse width, or wavelength selection. These parameter changes allow precise control of the curing process despite the compact nature of UVLEDs, maintaining measurement and control precision while benefiting from reduced weight and size.
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
Improves print quality by preventing ink bleeding and leveling, reduces the impact of ink contraction, and enhances printing speed by adjusting curing modes, while minimizing the size and weight of the UV light irradiation system.
Implementation Method 1
an ultraviolet light emitting diode (hereinafter, referred to as UVLED) is used as a light source for emitting ultraviolet light
Implementation Method 2
UV ink having a property that it is cured when irradiated with ultraviolet light
Data Source
AI summary
An inkjet printer including a UVLED unit which emits ultraviolet light to a print medium supported on a supporting table to cure UV ink droplets deposited on the print medium. The inkjet printer further includes a controller which adjust the light quantity of ultraviolet light, emitted from the UVLED unit to the UV ink droplets deposited on the print medium, from a light quantity for temporary curing to a light quantity for final curing, and a control unit capable of selecting between a two-stage curing mode in which UV ink droplets deposited on the print medium are temporarily cured ant are then finally cured and a single-stage curing mode in which UV ink droplets are finally cured by an irradiation with ultraviolet light at one time by means of the UVLED unit and the controller.