METHOD FOR APPLYING LAYERS ON A MATERIAL

• US 20170225500A1
• Filed: 02/01/2017
• Published: 08/10/2017
• Est. Priority Date: 02/05/2016
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Miller, Todd W.
• Granted Patent: US 10,259,236 B2
• Time in Patent Office: Days
• CPC Class Codes: A43B 1/0027 made at least partially from a material having special colours
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/024 Different layers of the same material
• CPC Class Codes: A43B 3/0078 provided with logos, letters, signatures or the like decoration A43B23/24 takes precedence
• CPC Class Codes: B05D 7/50 Multilayers
• CPC Class Codes: B05D 7/54 No clear coat specified
• CPC Class Codes: B05D 7/56 Three layers or more
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 70/682 Preformed parts characterised by their structure, e.g. form
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: B41J 11/00214 using UV radiation
• CPC Class Codes: B41J 11/20 Platen adjustments for varying the strength of impression, for a varying number of papers, for wear or for alignment , or for print gap adjustment
• CPC Class Codes: B41J 3/407 for marking on special material
• CPC Class Codes: B41J 3/4078 Printing on textile
• CPC Class Codes: B41M 5/0047 by ink-jet printing
• CPC Class Codes: B41M 5/0064 on plastics, horn, rubber, or other organic polymers
• CPC Class Codes: B41M 5/0076 on wooden surfaces, leather, linoleum, skin, or flowers
• CPC Class Codes: B41M 5/0088 by ink-jet printing
• CPC Class Codes: B41M 7/0081 : using electromagnetic radiation or waves, e.g. ultraviolet radiation, electron beams
• CPC Class Codes: D06P 1/525 : Polymers of unsaturated carboxylic acids or functional derivatives thereof
• CPC Class Codes: D06P 1/5285 : Polyurethanes; Polyurea; Polyguanides
• CPC Class Codes: D06P 1/5292 : containing Si-atoms
• CPC Class Codes: D06P 5/30 : Ink jet printing

Abstract

A process for printing multiple layers on a fabric or other material using UV-curable ink that includes a step of printing a first layer on the material and another step of partially curing the first layer. A next step includes printing a partially UV-transparent layer over the first layer and fully curing the UV-transparent layer while simultaneously fully curing the first layer.

Claims

1. A process for printing on a substrate using a printer and a material dispensed from the printer, comprising:

positioning the substrate on the printer;

printing a first layer of the material onto the substrate;

partially curing the first layer by subjecting the first layer to a first predetermined radiation event characterized by a first radiation;

printing a second layer of material over the first layer; and

fully curing the second layer and fully curing the first layer by subjecting the first layer and the second layer to a second predetermined radiation event characterized by a second radiation, wherein the second layer is partially transparent to the second radiation.

2. The process of claim 1, wherein the material dispensed from the printer flows down from high points in the first layer to low points in the first layer.

3. The process of claim 1, further comprising printing a third layer of material over the second layer and curing the third layer by subjecting the third layer to a third predetermined radiation event, wherein at least one of the first radiation and the second radiation is a UV radiation.

4. The process of claim 1, further comprising printing and curing at least an additional seven layers of material over the third layer.

5. The process of claim 1, wherein the printer has a print head, and wherein the process further comprises:

determining a first distance from the print head to the substrate prior to printing the first layer of material; and

adjusting a second distance from the print head to the first layer after the first layer has been printed and partially cured but prior to printing the second layer, such that the second distance from the print head to the first layer after the first layer is printed on the material is equal to the first distance.

6. The process of claim 1, wherein the second predetermined radiation event is characterized by a second radiation incident intensity and a second radiation duration, and wherein at least one of the second radiation incident intensity and the second radiation duration is adjusted based upon a magnitude of transmission of the second radiation through the second layer of material.

7. The process of claim 1, wherein the first predetermined radiation event comprises subjecting the first layer to UV radiation for a duration within the range of from 0.03 to 0.20 seconds.

8. The process of claim 1, wherein a thickness of the first layer is in a range of from 0.05 to 0.2 mm.

9. The process of claim 1, wherein the second layer has a flat top surface, and wherein the flat top surface of the second layer serves as a flat reference layer for printing subsequent layers.

10. The process of claim 1, wherein the first layer is printed with a pattern of openings in the first layer.

11. A process for printing on a substrate that has an uneven top surface, comprising:

positioning the substrate on a printer;

printing a first layer of a material onto the uneven top surface of the substrate;

partially curing the first layer by exposing the first layer to a first predetermined radiation event;

allowing the first layer to coalesce such that a top surface of the first layer is smoother than the uneven top surface of the substrate;

printing a second layer of material over the first layer; and

curing the second layer and fully curing the first layer by subjecting the second layer to a second predetermined radiation event.

12. The process of claim 11, wherein the material dispensed from the printer flows down from high points in the first layer to low points in the first layer.

13. The process of claim 11, wherein at least one of the first predetermined radiation event and the second predetermined radiation event is a UV radiation event, and wherein the second layer is fully cured.

14. The process of claim 11, wherein the second layer is partially cured.

15. The process of claim 11, wherein the second layer coalesces during curing, such that a top surface of the second layer is smoother than the top surface of the first layer.

16. The process of claim 11, further comprising allowing the second layer to coalesce, such that a top surface of the second layer is flatter than the top surface of the first layer.

17. The process of claim 11, further comprising printing and curing additional layers, wherein at least one additional layer has a flat top surface that serves as a reference layer for subsequent processes.

18. The process of claim 11, wherein each layer has a thickness in range from 0.05 mm to 0.2 mm.

19. The process of claim 11, wherein the printer has a print head, further comprising adjusting a distance from the print head to the top surface of the first layer prior to printing the second layer.

20. The process of claim 11, further comprising printing a topmost layer of material, wherein a sufficient number of additional layers are printed to ensure that a top surface of the topmost layer of material meets a predetermined target level of smoothness.

21. The process of claim 11, further comprising printing a topmost layer of material, wherein the sufficient number of additional layers are printed to ensure that a top surface of the topmost layer of material meets a predetermined target level of flatness.

22. A process for printing onto a substrate using a printer comprising:

positioning the substrate on the printer;

printing a first layer of material on the substrate, the first layer having a pattern of openings;

partially curing the first layer by subjecting the first layer to a first radiation event;

printing a second layer of material over the first layer; and

partially curing the second layer and further curing the first layer by subjecting the second layer to a second radiation event;

wherein the first layer of material expands into the pattern of openings as it is cured to at least partially fill in the pattern of openings.

23. The process of claim 22, wherein the pattern of openings is a pattern of grooves.

24. The process of claim 22, wherein at least one of the first radiation event and the second radiation event is a UV radiation event.

25. The process of claim 22, wherein the printer has a print head, further comprising adjusting a distance from the print head to the first layer prior to printing the second layer.

26. The process of claim 22, wherein a thickness of the first layer is in a range of from 0.05 to 0.2 mm.

27. The process of claim 22, wherein the first radiation event comprises subjecting the first layer to UV light for a duration within the range of from 0.03 to 0.20 seconds.