Inline Web Coating and UV Curing for Plastic Sheet Production
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Solution Overview
Problem
Existing methods for producing printed sheets from a web are limited in their applicability to various materials, particularly not being suitable for plastic, and lack efficiency in processes like cold foil transfer and embossing.
Innovation Solution
A method and device for producing printed sheets from a web that includes applying a fluid as an adhesive or embossing layer, transferring and curing it using UV radiation, and then cutting and printing, allowing for inline processing with a device comprising unwinding, coating, film transport, cross-cutting, and printing stations, suitable for paper, cardboard, or plastic webs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional coating and printing methods are used on plastic webs, then the process is simple, but the adhesive fluid cannot be properly bonded and the material is not suitable for plastic
Solution Approach 1:
The patent applies UV irradiation to change the physical-chemical state of the adhesive fluid, transforming it from a liquid state to a cured state through photopolymerization. This parameter change enables proper bonding on plastic surfaces that are incompatible with conventional adhesives
Solution Approach 2:
The patent replaces conventional thermal or mechanical bonding methods with UV radiation curing. This substitution allows the adhesive to bond effectively to plastic surfaces without requiring heat or pressure that would damage the plastic material
2Manufacturing precision
If cold foil transfer or embossing processes are used, then surface finishing is achieved, but the process requires separate operations and is time-consuming
Solution Approach 1:
The patent combines the adhesive coating, foil transfer, embossing, and UV curing operations into a single integrated process line. The web passes through all stations sequentially without interruption, merging multiple separate operations into one continuous process that maintains surface finishing quality while dramatically improving productivity
Solution Approach 2:
The adhesive is applied and cured in advance before the final printing operation. This preliminary action prepares the surface for subsequent printing while allowing the web to move continuously through the system, reducing total production time
3Ease of operation
If the web is cut into sheets before printing, then individual sheets can be processed, but material aging occurs and processing time increases
Solution Approach 1:
The web is cut into individual sheets and the adhesive is cured in advance, before the sheets undergo any aging or further processing. This preliminary cutting and curing eliminates the need to handle and reposition large webs during subsequent printing operations, reducing processing time while preventing material aging
Solution Approach 2:
The continuous web is segmented into individual sheets at a specific point in the process. This segmentation allows each sheet to be processed independently through the printing station without interference from adjacent sheets, improving ease of operation while maintaining continuous production flow
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
Enables efficient production of printed sheets from diverse materials, including plastic, with improved surface finishing and printing quality by ensuring the fluid is effectively bonded and hardened, facilitating inline processing without material aging issues.
Implementation Method 1
the adhesive can be placed between of the transferred transfer layer and the web can be cured by UV irradiation to firmly bond the transfer layer to the web
Implementation Method 2
before the third step, the embossing layer on the web can be hardened by UV radiation in order to permanently strengthen the surface structure
Data Source
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AI summary
In a process for producing printed sheets (9) from a web (1), in a first step the web (1) or a film (24) is coated with a fluid, then in a second step the web (1) is treated using the film (24), then in a third step the web (1) is cut into sheets (9) and then in a fourth step the sheets (9) are printed.