System and Method for Scoring and Applying a Pigment Solution to a Substrate

Abstract

A system for scoring a curved surface of a manufactured product is provided. The system includes: a controller unit for analyzing a digital image to be printed to the curved surface of the manufactured product; and an ink-jet printer in communication with the controller unit and including a printhead including one or more fluid reservoirs, each of which includes a curable solution, for applying the curable solution to the curved surface in a pattern directed by the controller unit and based on the digital image. The system also includes: a radiation generator in communication with the controller unit which applies radiation to the curved surface to cure the curable solution applied by the ink-jet printer; and a fluid pressurizer in communication with the controller unit for providing a pressurized fluid stream to the curved surface.

The invention claimed is: 
     
         1 . A system for scoring a curved surface of a manufactured product, the system comprising:
 a controller unit for analyzing a digital image to be printed to the curved surface of the manufactured product;   an ink-jet printer in communication with the controller unit and including a printhead comprising one or more fluid reservoirs, each of which contains a curable solution for applying the curable solution to the curved surface in a pattern directed by the controller unit and based on the digital image;   a radiation generator in communication with the controller unit which applies radiation to the curved surface to cure the curable solution applied by the ink-jet printer; and   a fluid pressurizer in communication with the controller unit for providing a pressurized fluid stream to the curved surface,   wherein at least a portion of the curable solution applied to the curved surface by the ink-jet printer does not erode when exposed to the pressurized fluid stream, and wherein portions of the curved surface not covered by the curable solution are eroded to form an eroded region of the curved surface.   
     
     
         2 . The system of  claim 1 , wherein the manufactured product is formed from one or more of the following materials: glass, plastic, metal, and ceramic. 
     
     
         3 . The system of  claim 1 , wherein the manufactured product comprises one or more of: dinnerware, kitchen utensils, drinkware, serverware, coasters, plaques, name tags, timepiece faces, bottles, containers, and cans. 
     
     
         4 . The system of  claim 1 , wherein the curable solution contained in the one or more fluid reservoirs comprises an ink which is cured by exposure to ultraviolet light, and wherein the radiation generator applies ultraviolet light to the curved surface of the manufactured product to cure the curable solution applied thereto. 
     
     
         5 . The system of  claim 1 , wherein the pressurized fluid stream comprises a fluid mixture containing an abrasive agent. 
     
     
         6 . The system of  claim 5 , wherein the abrasive agent comprises one or more of the following: silica, sand, garnet, hard synthetic particles, aluminum oxide, silicon carbide, and carborundum. 
     
     
         7 . The system of  claim 1 , wherein the controller unit is configured to:
 obtain the digital image of a design to be printed on the curved surface; and   analyze the digital image to determine a series of instructions for controlling the ink-jet printer.   
     
     
         8 . The system of  claim 7 , wherein the controller unit is configured to cause the printhead to move over the curved surface of the manufactured product based on the generated instructions to apply the first curable solution contained in the first fluid reservoir to a portion of the curved surface of the manufactured product. 
     
     
         9 . The system of  claim 8 , wherein the controller unit is further configured to:
 after the first curable solution is applied, cause the radiation generator to apply radiation to the curved surface to cure the first curable solution to form a cured region; and   cause the fluid pressurizer to apply the fluid stream for eroding the curved surface of the manufactured product to at least a portion of the curved surface including the cured region, thereby removing portions of the manufactured product, which are not covered by the cured region, to form an eroded region on the curved surface of the manufactured product.   
     
     
         10 . The system of  claim 1 , wherein the printhead comprises a first fluid reservoir containing a first curable solution, a second fluid reservoir containing a second curable solution, and a third fluid reservoir containing a third curable solution. 
     
     
         11 . The system of  claim 10 , wherein one or more of the curable solutions comprises one or more of: cyan pigments, magenta pigments, yellow pigments, black pigments, and combinations thereof. 
     
     
         12 . The system of  claim 10 , wherein the controller unit is configured to:
 cause the printhead to move over the curved surface of the manufactured product according to the pattern based on the digital image to apply the first curable solution contained in the first fluid reservoir to a portion of the curved surface of the manufactured product;   after the first curable solution is applied, cause the radiation generator to apply radiation to the curved surface to cure the first curable solution to form a cured region; and   cause the fluid pressurizer to apply the pressurized fluid stream for eroding the curved surface of the manufactured product to at least a portion of the curved surface including the cured region, thereby removing portions of the manufactured product, which are not covered by the cured region, to form an eroded region on the curved surface of the manufactured product.   
     
     
         13 . The system of  claim 12 , wherein the controller is further configured to:
 following formation of the eroded region, cause the printhead to move over the curved surface of the manufactured product a second time according to the pattern based on the digital image to apply the second curable solution from the second fluid reservoir to at least a portion of the eroded region of the curved surface of the manufactured product; and   after the second curable solution is applied, cause the radiation generator to apply radiation to the curved surface to cure the second curable solution to form a base layer on at least a portion of the eroded region.   
     
     
         14 . The system of  claim 13 , wherein the second curable solution comprises a substantially white pigment. 
     
     
         15 . The system of claim of  claim 13 , wherein the controller unit is further configured to:
 following formation of the base layer, cause the printhead to move over the curved surface according to the pattern a third time and apply the third curable solution from the third fluid reservoir to at least a portion of the base layer; and   after the third curable solution is applied, cause the radiation generator to apply radiation to the curved surface curing the applied third curable solution from the third fluid reservoir to form a pigment layer over the base layer.   
     
     
         16 . The system of  claim 15 , wherein the third curable solution comprises pigments of a different color from pigments of the second curable solution. 
     
     
         17 . The system of  claim 15 , wherein the third curable solution comprises one or more of the following pigments: cyan pigments, magenta pigments, yellow pigments, and black pigments. 
     
     
         18 . The system of  claim 1 , wherein the radiation generator comprises an ultraviolet lamp or bulb.