Variable Gloss Control via LED Curing Power in Thermoforming
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Solution Overview
Problem
Current methods for thermoformed display graphics lack control over gloss levels, with the finish being limited to the capabilities of the printer and requiring post-production processes like printing on clear materials or applying coatings, which restricts variability and flexibility.
Innovation Solution
The method involves using thermoforming inks with LED UV curing systems and varying the power levels of LED curing lamps to achieve selective gloss control on thermoformed substrates, followed by heat treatment to develop the glossy finish, allowing for variable gloss levels on the outward surface without the need for clear materials or post-production coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If printing is performed on the outward surface of thermoforming material using conventional methods, then the image can be displayed directly on the visible surface, but the gloss level cannot be controlled and is limited to the capabilities of the printer
Solution Approach 1:
The invention changes the parameter of LED curing lamp power levels to control the degree of ink curing. By varying the power levels, different degrees of curing are achieved, which directly controls the gloss level of the printed image after thermoforming. This allows precise control of gloss from matte to high gloss on the outward surface without changing the printing method.
Solution Approach 2:
The invention performs preliminary curing of the ink on the outward surface using LED UV lamps before the thermoforming process. This preliminary action creates a cured layer that will later transform into different gloss levels during thermoforming, enabling gloss control to be established in advance rather than requiring post-processing.
2Manufacturing precision
If the second surface printing method is used to achieve glossy finish, then the image can be viewed through clear material with glossy appearance, but the gloss level is limited to the media capability and the printing process becomes more complex
Solution Approach 1:
The invention inverts the conventional second surface printing approach by printing directly on the outward (first) surface and using selective curing to achieve gloss control. Instead of printing through clear material from the back, the method prints on the visible surface and controls gloss through differential curing, simplifying the process while maintaining gloss control capability.
Solution Approach 2:
The invention applies local quality by selectively curing different regions of the printed image with different LED power levels. This creates variable gloss levels in different areas of the same print, allowing some regions to be matte while others are glossy, all on the outward surface without requiring clear material or complex multi-step processes.
3Manufacturing precision
If post-production processes are applied to achieve variable gloss levels, then gloss control can be achieved, but additional processing steps and materials are required
Solution Approach 1:
The invention merges the printing and gloss control processes into a single integrated operation. By using LED UV lamps with variable power levels during the printing stage, both image application and gloss level determination are accomplished simultaneously. The thermoforming process then transforms these differently cured regions into the final variable gloss finish, eliminating the need for separate post-production gloss control steps.
Solution Approach 2:
The invention enables the printed image to self-determine its gloss levels through the thermoforming process. The differentially cured ink layers automatically transform into different gloss finishes during thermoforming without requiring additional coatings, laminates, or post-treatment processes. The system uses the thermoforming heat to complete the gloss development that was initiated during printing.
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 precise control over gloss levels on thermoformed materials, transforming matte finishes into higher gloss finishes through heat treatment, offering flexibility and variability not previously achievable with conventional methods.
Implementation Method 1
The idea of gloss control is not new and can be achieved through other methods on conventional substrates. However, achieving variable levels of gloss on thermoformed images normally requires the application of some sort of spray-on coating or thermoformable laminate. Currently, someone who wanted their thermoformed image to have a higher level of gloss finish would have limited options. One option would be to print their image reversed on a clear sheet of thermoformable material, in a second surface method, which would provide a gloss finish at the level provided by the clear material that the image is displayed behind. Other ways to achieve a gloss finish would be to have some post-production process, either between printing and forming, e.g. applying a laminate or coating, or after thermoforming, e.g. spraying on a coating.
Implementation Method 2
However, heat treating of the substrate, for example during thermoforming or in an oven, develops the glossy finish on the substrate in relation to the level of power applied to the printer LED curing lamps during printing.
Data Source
AI summary
Thermal transformative variable gloss control produces selectively variable levels of gloss finish on thermoformed materials. In embodiments, the power level of LED curing lamps associated with an ink jet printer that is using thermoforming inks for printing is selectively varied depending upon a desired level of gloss in a finished substrate. Heat treating of the substrate during thermoforming or in an oven develops the glossy finish on the substrate in relation to the level of power applied to the printer LED curing lamps during printing.