Systems and methods of UV printing on substrates

A system and method for printing patterns on a substrate, including a substrate; a powder; a sealing coating; and a UV curable paint; wherein the powder, the sealing coating and the UV curable paint are deposited onto the substrate and heated and cured. The method is designed to make the substrate have a faux appearance with lower costs than manufacturing the real substrate it was meant to look like.

FIELD OF THE TECHNOLOGY

The present device, system, and methods is related to the field of printing on substrates utilizing ultraviolet (UV) light or radiation, and in particular to, the printing of patterns on substrates that can be used in connection with grill surfaces, fire pits and mantels, and other furniture.

BACKGROUND

UV-curing printing inks have been known in the art for some time. Though, it is only recently that UV-printing inks which from some aspects are adequate for industrial use have been developed, especially when referring to lowering the cost of production of household items such as tables, heaters, grills, and the like. In addition, in the last few years, UV-curing has become more useful due to advances in the technology of UV lamps and curable materials. Application of UV-curing coatings can now be processed with sheetfed, web and wide-format inkjet equipment. Even so, although UV-printing systems and methods are disclosed, less costly, more efficient systems and methods are needed which can be used on other substrates not before contemplated.

SUMMARY

Example aspects described herein relate generally to the printing or depositing of patterns and such and, more particularly, to UV printing systems, and more specifically to deposition of a liquid or solid coating, or a mixture thereof which is curable by UV light.

Accordingly, this disclosure details implementations for a UV light system for depositing a design or pattern on a substrate.

In one aspect, the present disclosure provides a method for printing or depositing a faux design on a workpiece by providing a workpiece defining at least one surface, coating the at least one surface of the workpiece with a substantially transparent achromatic color coating or a color that fully reflects and scatters all the visible wavelengths of light, exposing the workpiece to a heat source at a predetermined temperature for a predetermined time, providing a robotic device configured for printing or depositing a design onto the at least one surface, the robotic device including a computing device, a printing head, a table, a memory, a processor, and at least one UV curable substance, disposing the workpiece about the table of the robotic device, configuring the robotic device according to the workpiece, selecting a design from a listing of predetermined designs configured according to the workpiece, processing the design with the processor and the computing device, instructing the robotic device to deposit the at least one UV curable substance according to the design onto the at least one surface while exposing the design to a UV light for a predetermined time, depositing the at least one UV curable substance according to the design onto the at least one surface, applying at least one layer of a substrate sealant to the at least one surface and the at least one UV curable substance, optionally applying at least one layer of a second UV curable substance onto the at least one surface, applying heat to the at least one surface and the second UV curable substance for a predetermined amount of time at a predetermined temperature, and exposing the workpiece to UV radiation emitted from a UV source for a predetermined amount of time at a predetermined temperature, such that the design is permanently affixed to the workpiece to provide a faux design.

In another aspect, the present disclosure provides a method of printing patterns on a substrate including providing a well buffed and clean workpiece or mantel, coating the mantel with a white colored powder and curing the powder coating by exposing the mantel to heat at about 220 degrees C. for about 30 min, placing the mantel at a designated location above a working table of a printer connected to a computing device, adjusting the height of a printing head of the printer manually according to the mantel's height and setting a starting point, selecting a design from a listing of predetermined designs stored in a memory of the computing device, processing the selected design via a processor of the computing device, communicating the selected design to the printer, providing a light source configured to provide light to the mantel where the light source is coupled to the printer and the printer includes a UV curable ink, instructing the printer to deposit the selected design onto the at least one surface, activating a UV lamp until the printer reaches a normal working power and moving the printing head to a starting point of the mantel; depositing the selected design onto the mantel and displaying the advancement of the deposition of the design onto the mantel on a display of the computing device, spraying the mantel with a substrate paint allowing the substrate paint to dry for a predetermined time, spraying a UV paint onto the mantel, exposing the mantel to an oven set at a predetermined temperature for a predetermined time for volatilizing a diluent within the UV paint, and exposing the mantel to a UV curing zone having a UV light configured to irradiate UV light to the mantel, such that the selected design is permanently affixed to the mantel providing a faux appearance.

DETAILED DESCRIPTION

In reference toFIGS. 1-16, the present disclosure relates to printing, additive manufacturing, and deposition of a design (such as a faux design) onto a workpiece. The design is associated with UV curable coatings (which may include UV curable substances) and patterns, such as camouflage patterns, symbols and shapes patterns, a wood finish pattern, a stone or rock look pattern, and line patterns, ceramic tile patterns, concrete patterns, and all other patterns that can be designated by computer which are cured or dried onto a workpiece or a portion thereof under the action of UV radiation. Specifically, the present disclosure relates to depositing a UV coating or a coating including a UV curable element according to a predetermined design onto a workpiece100such that the workpiece can have an aesthetically attractive, faux look.

With reference toFIGS. 1-3, a workpiece100is presented including at least one surface110, and defining a body120. In embodiments, the workpiece100may be a workpiece (or a portion thereof) selected from a table, floor vinyl, floor tile, fire pit, house decoration insert, mantel, or the like. The workpiece100may be configured using materials such as resin, metal, glass, and ceramic and alloys, and after disposing a design replicating the look or appearance of materials like wood, marble, grouted tile patterns, concrete, quartz, and granite. Moreover, the workpiece100may be manufactured via well-known manufacturing methods such as additive manufacturing, molding, machining, or the like. In embodiments, the workpiece100is configured as a mantel made out of wood or metal and the body120of the workpiece100is configured into a cylindrical shape (as shown in exemplary embodiments depicted inFIGS. 1-14). In other words, the body120is configured similarly to a disk including a body perimeter121configured to wrap around the body120which is configured to receive a UV coating. In alternative embodiments, the workpiece100may be any other shape required for the finished product, including square, rectangle, oval, triangle, etc.

Prior to receiving a UV curable coating200, the at least one surface110may be buffed and/or coated with an initial coating including a substantially transparent achromatic color or a color that fully reflects and scatters all the visible wavelengths of light. For example, the at least one surface110can include at least one layer of a coating130of a white coating111, as shown inFIG. 1. The application of the at least one layer of coating130onto the workpiece100may be via spraying, spreading, brushing or other suitable methods. In embodiments, more than at least one layer of coating130may be required. For a workpiece100manufactured via molding, the coating130may be applied to a mold (not shown) before or during the forming of the molded workpiece100. For example, if the molded workpiece100is made out of a resin (not shown) configured to take the shape of the mold (not shown), the coating130maybe applied to the mold (not shown) prior to filling the mold with the resin material. Specifically, a surface (not shown) of the mold (not shown) configured to engage the resin (not shown) is configured to receive the coating130. It is understood that selected workpieces100may not need a coating130before receiving the UV curable coating200. For a workpiece100including the coating130, after the coating130is disposed on the workpiece100the coating130along with workpiece100may be exposed to heat to enhance or enable adhesion of the coating130onto the workpiece100. For example, the coating130and the workpieces100may be inserted in an oven set at a predetermined temperature, from about e.g. 200 to about 250 degrees Celsius, for a predetermined period of time, from about 20 to about 50 minutes). In selected embodiments, the coating130may be applied in layers of from approximately 0.001 to approximately 0.1 inches in thickness. In examples, the coating130may be commercially available (from Fujian Wanan) and may include components such as an epoxy ethyl methyl, a thermoplastic such as low density polyethylene (LDPE), mercapatobenzothiazole zinc salts, and the like in selected ratios, for example, but not limited to the following ratios:

With reference toFIGS. 4 and 5, after the application of the coating130, a UV curable coating200is deposited onto the workpiece100above the at least one layer of coating130according to design800. The design800is described in further detail hereinbelow.FIG. 4shows a display illustrating a computer program (below noted as computer program302) exhibiting a schematic image of the workpiece100with the UV curable coating200deposited onto the at least one layer of coated surface prior to depositing the UV curable coating200onto the workpiece100.FIG. 5shows the processing of the schematic image associated with the workpiece100and the UV curable coating200depositing of the UV curable coating200onto the workpiece100. The UV curable coating200may be selected from a UV curable paint or a UV curable inks, a surface sealant, an adhesive, a strainer, a polymer, an acrylate, a paint, a pigment, or other suitable coating. In embodiments, the at least one surface110may be further configured to receive other non-UV curable coatings or a combination of the UV curable coating200and a non-UV curable coating. In embodiments, the UV curable coating200may be an Inkjet ink including coatings listed in the table hereinbelow:

In selected embodiments, the UV curable coating200may be an Inkjet ink including the following physical and chemical properties:

Turning now toFIGS. 6-9, the UV curable coating200can be deposited onto the workpiece100via electrical or a non-electrical device. The non-electrical device may be selected from a pen, a pencil, a brush, a chisel, or a user's hand. The electrical devices may be selected from hand-held devices or non-hand-held devices. The hand-held are devices generally powered by electricity (or systems storing energy) and are configured to fit in a human hand, for example, a rotary tool, perforating or punching tools, toner/ink disposing apparatus (such as tattoo-machines, or hand-held printers), a 3D-pen, or the like. The non-hand-held devices are powered by electricity and are generally more complex devices such as robotic devices, for example, 3D printers, CNC mills, CNC printers or the like. As seen inFIGS. 6-9(orFIGS. 2 and 3), a robotic device300may be configured to deposit the UV curable coating200onto the workpiece100. The robotic device300includes a computing device310, a bed320, a printing head330, a moving rail340, at least one memory (not shown), and at least one processor (not shown). The bed320includes a working space321, a plane322(FIG. 3), and a coordinate system323including directions X, Y and Z, and may be stationary. Alternatively, the bed320may be configured to move with reference to the printing head330or the computing device310. In embodiments, the working space321includes an initial reference point321a. The initial reference point321aor point321amay be a point disposed adjacent to the working piece100or disposed about the coordinate system323and above the plane322. Alternatively, the initial reference point321amay be a point disposed along the body perimeter121. As shown in an examplary embodiment depicted inFIGS. 1 and 2, the initial reference point321ais disposed adjacent to the at least one surface110. In selected embodiments, the initial reference point321ais the central point of the coordinate system323and the two may be defined by the use of the computing device310relative to the position of the workpiece100. The computing device310is configured to communicate with the printing head330and includes a display331. The computing device310of the robotic device300is configured to include at least one memory (not shown) and at least one processor (not shown). The printing head330is configured to communicate with the computing device310and is operably connected to the moving rail340. Generally the printing head330is configured to move along the moving rail340(FIGS. 6 and 7) and in selected embodiments it may be configured to move along the Z direction of the coordinate system323. The moving rail340is operably connected to the bed320and is configured to move along one direction about the bed320, in embodiments, along the Y direction of the coordinate system323. In embodiments, the bed320may be further configured to receive more than one workpiece100.

Specifically, with reference toFIG. 6(orFIGS. 2 and 3), the printing head330is generally configured to deposit the UV curable coating200and other types of coating (e.g. ink, paint) onto the workpiece100according. For example, the printing head330maybe a Seiko printhead configured to carry and deposit a UV curable coating200such as UV curable inkjet ink for the Seiko printhead. Moreover, the printing head330may be further configured to include at least one cartridge331configured to the store the UV curable coating200. In embodiments, the printing head330may be configured to connect to at least one UV light source330. Alternatively, the UV light source330may be coupled to a selected portion of the device300instead of the printing head330.

In general, the UV light source330is configured to emit a UV light onto the workpiece100during deposition of the UV curable coating200(FIGS. 7-8). The UV light source330may include a UV bulb (not shown) or a UV radiation source with a working power of about 300 watts to about 600 watts (e.g. a medium pressure mercury lamp). In embodiments, the UV light source330may be configured to generate a specific wavelength to cure inks or coatings (such as UV coatings), thus, wattage may vary depending on a desired wavelength. The UV lamp330may include a configuration of about 140 mm to about 180 mm in size. In embodiments, the UV lamp330may be made of quartz and a UV inner gas (not shown) composition may comprise argon. Alternatively, iron and gallium may be added to the UV inner gas composition to achieve a predetermined wavelength. In embodiments, a medium pressure fluorescent arc lamp may be utilized in order to provide ultraviolet radiation. The UV lamp330may be in communication with the robotic device300or can be manipulated manually. The UV lamp330may be configured to emit UV radiation (or UV light) according to a selected process. For example, robotic device300may be configured to emit a blinking UV light which may slow down the curing reaction of the coatings deposited onto the working piece100. In embodiments, the robotic device300may be further configured to depose one or more design800(or an alternative design (not shown)) onto more that one workpiece100.

Turning now toFIGS. 10-14, after depositing the UV curable coating200according to the preselected design800onto the at least one surface110of the workpiece100(FIG. 9) at least one layer of a substrate sealant400(alternatively it may be white coating111) is deposited onto the at least one surface110. The substrate sealant400may be deposited onto the at least one surface110via a spraying gun410or other suitable device configured for applying at least one layer of the UV curable coating200onto the at least one surface (FIG. 10). In embodiments, the sealing paint thickness may be from about 0.001 inches to about 1 inch. For example, the substrate sealant400is a sealing paint400which may include about 60% of an acrylic resin, about 7% of a curing agent, and about 33% of a butyl ester (commercially available by Bayer AG).

Furthermore, an additional layer of UV curable coating500is applied to the at least one surface110via a spraying gun410′ (FIG. 5). The UV curable coating500can be similar or substantially similar to the UV curable coating200. The UV curable paint300may be deposited as a coat of a thickness from about 0.001 inches to about 1 inch depending on the application. In embodiments, a square meter area of the at least one surface110may include about 75 grams to 150 grams of the UV curable coating500or UV curable paint500. In embodiments, the UV curable paint500may be translucent, transparent, or opaque. In one example, the UV curable paint500may have the following components by weight (commercially available by Guangdong Shenzhen Industrial Co.):

Finally, the at least one surface110of the workpiece100is exposed to heat and then to a UV light (or UV radiation), each exposure for a predetermined amount of time at a predetermined temperature. For example, the at least one surface110is exposed to the heat emitted by a heating device600(FIG. 12). The heating device600may be an oven600including a heat source610, a heating chamber620, and a conveyor belt630. The heat source610is generally disposed above the conveyor belt630and the conveyor belt630is disposed near the heating chamber620. The heat source610is configured to drive heat into the heating chamber620. The heating chamber620is configured to receive the workpiece100(or a plurality of workpieces100) therethrough. As shown inFIG. 12, the workpiece100and a workpiece100′ are disposed onto the conveyor belt630while the conveyor belt630is transporting the workpiece100′ and the workpiece100into the heating chamber620. The heating device600may be set to a temperature between about 50 to about 100 degrees Celcius and may be configured to apply heat onto the workpiece100for a time between about 10 to about 30 minutes.

With reference toFIG. 13, the at least one surface110is further exposed to a second UV light irradiated by a UV machine700. The UV machine700includes a UV light source (not shown) or a UV lamp (not shown), a UV irradiation zone710, and a conveyor730. The conveyor belt730is configured to transport the workpiece into the UV irritation zone710. The UV irradiation zone710is configured to receive the workpiece100(or a plurality of workpieces100) therethrough. As shown inFIG. 12, the workpiece100is disposed onto the conveyor belt730while the conveyor belt730is transporting the workpiece100into the UV irradiation zone710. The UV machine700may be set to an intensity of about 500 watts to about 700 watts, in embodiments about 600 watts, UV radiation during a predetermined time period of about 10 to about 30 minutes, in embodiments about 15 to about 25 minutes. For selected embodiments, the UV machine700may be included in an assembly line (e.g. assembly line900—FIG. 17) further disposed adjacent to the heating device600. Thus, it may be desired to have the conveyor belt630aligned or connected with the conveyor belt730.

Turning now toFIGS. 15-17(in view ofFIGS. 1-14), exemplary methods and configurations to carry the methods for depositing a UV curable coating200and/or design800onto workpiece100are provided. As noted above, the workpiece100or a portion thereof such as the at least one surface110is configured to receive a plurality of coatings according, more specifically, a UV curable coating200and the design800. As shown inFIGS. 1-3, the at least one surface110is configured to receive a UV curable coating200, specifically, the at least one surface110may be buffed and coated with a substantially transparent achromatic color coating111(shown as a white substance inFIGS. 1-3). The quantity of coating111disposed onto the at least one surface110may be selected relative to the dimensions of the surface to be treated (e.g about 50 grams to 100 about grams). After configuring the workpiece100to receive the UV curable coating200, the workpiece100is disposed onto the working space321between the bed320and the moving rail340. Moreover, the robotic device300is configured to define a location of the workpiece100relative to the working space321and further define a starting point or point321afor the printing head330to begin depositing the design800onto the at least one surface110. InFIG. 3, the printing head330is configured at a predetermined working height “WH” according to a predetermined distance or thickness “T” of the workpiece100, the working height “WH” may be the distance between the printing head330and at least one surface110of the workpiece100. The printing head330of the robotic device300is configured to communicate with the computing device330; the computing device330being configured to store the design800. A user can visualize the design800(or a list of designs from which a design800can be chosen from) on the display331(FIG. 4) and further modify the design800if needed. After selecting the design800, the design800is processed at the computing device330(FIG. 5). The robotic device300is instructed to deposit the design800onto the at least one surface110of the workpiece100. In embodiments, the robotic device300may only begin depositing the design800and begin a photochemical process where a UV light source330is used to cure the UV curable coating200after the robotic device300reaches a normal working power (selected depending on the conditions of the machine, design, material) and/or when the UV lamp is lit for about 2 to about 7 minutes, in embodiments after about 3 minutes (time subject to change according to a particular substrate). For configurations where the robotic device300is part of an assembly line, the robotic device300may only be required to reach the normal working power prior to depositing the UV curable coating200onto a first workpiece300. Some may describe or encompass the deposition of the design800and the UV curable coating200in a printing process where the design800is printed onto the at least one surface110which starts after the printing head330moves to a start location as seen inFIG. 6. The printing process can be computer-controlled, as shown inFIG. 8, wherein the printing process may be controlled by the robotic device300. The robotic device300(or computer software302stored in the robotic device300) may include an indicator301configured to aid visualization of the printing process. The indicator301may be associated with the movement of the printing head330. In selected embodiments, the computer software302may be any printing software known in the art (such as PrintExp.exe and/or UltraPrint.exe).

After deposition of the design800and/or the UV coating200onto the at least one surface110, the at least one surface110or a portion thereof may be covered with at least one layer of the coating sealant400(FIG. 10) discussed hereinabove, followed by application of at least one layer of the UV curable coating500(FIG. 11). Additional layers of the coating sealant400or the UV curable paint500may be applied to the at least one surface110until reaching a desired appearance or texture.

After a desired amount or layers of UV curable coating500is sprayed onto the at least one surface110, the at least one surface110is exposed to heat emitted via a heating device such as the heating device600. At the heating device600, the workpiece110is disposed onto the conveyor belt630and passed through the heating device heating chamber620which is configured to bake or cure the UV curable paint500(and/or coatings deposited below said layer), so as to volatilize any diluents.

Additionally, after the workpiece100leaves the heating device600, the workpiece100is exposed to UV light via the UV machine700. At the UV machine700the workpiece100passes through the UV irradiation zone710or UV curing zone710. The UV machine700may include a UV lamp (not shown) having a working power of about 600 watts. In embodiments, the UV machine700may be configured to emit a blinking UV light which may slowdown the curing reaction of the coatings deposited onto the working piece100. Ultimately the workpiece100is removed from the UV machine700with the design800shown thereon.

The embodiments disclosed herein are examples of the disclosure and may be embodied in various forms. For instance, although certain embodiments herein are described as separate embodiments, each of the embodiments herein may be combined with one or more of the other embodiments herein. Specific structural and functional details disclosed herein are not to be interpreted as limiting, but as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure in virtually any appropriately detailed structure Like reference numerals may refer to similar or identical elements throughout the description of the figures.