Aqueous Gravure Ink Formulation for High-Resolution Printing
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Solution Overview
Problem
Aqueous gravure inks face challenges in achieving high-resolution printing with environmental sustainability due to issues like high surface tension, poor drying properties, and color unevenness, which are not adequately addressed by existing non-toluene inks that fail to reduce volatile organic compounds and CO2 emissions.
Innovation Solution
An aqueous gravure ink formulation containing a pigment, a polymer, a water-soluble organic solvent with a glycol ether having a boiling point between 100°C and 260°C, an acetylene glycol-based surfactant, and a high water content, which improves leveling properties and reduces environmental burden by minimizing the need for solvent dilution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional non-toluene inks are used, then working environment is improved, but volatile organic compounds and CO2 emissions are not reduced
Solution Approach 1:
The patent changes the chemical composition parameters of the ink by using water as the primary solvent (50-80 mass%) instead of conventional organic solvents like toluene. The ink contains 0-15 mass% alcohol and 0-20 mass% glycol ether, creating a water-based formulation that reduces volatile organic compounds while maintaining printing performance. This parameter change directly addresses the contradiction by eliminating harmful organic emissions while improving working conditions.
Solution Approach 2:
The patent creates a composite aqueous ink system combining water, alcohol, glycol ether, polymer, and pigment in specific proportions. This composite formulation replaces conventional organic solvent-based inks while achieving both environmental sustainability and printing quality. The synergistic combination of multiple components resolves the contradiction between environmental protection and functional performance.
2Object-generated harmful factors
If water is used as main solvent, then environmental burden is reduced, but surface tension increases causing poor wettability and leveling properties
Solution Approach 1:
The patent introduces glycol ether (0-20 mass%) and alcohol (0-15 mass%) as intermediary substances that mediate between water and the printing substrate. These intermediaries reduce the surface tension of the aqueous ink system, improving wettability and leveling properties without compromising the environmental benefits of water-based formulation. The glycol ether and alcohol act as surfactants that facilitate ink spreading and uniform distribution.
Solution Approach 2:
The patent formulates a composite aqueous ink system where water (50-80 mass%) is combined with alcohol (0-15 mass%) and glycol ether (0-20 mass%) in specific ratios. This composite material achieves both low environmental burden and excellent wettability by leveraging the synergistic effects of its components. The polymer (5-30 mass%) further contributes to film formation and leveling, resolving the contradiction between environmental sustainability and operational performance.
3Object-generated harmful factors
If high water content is used, then volatile organic compounds are reduced, but drying properties deteriorate
Solution Approach 1:
The patent optimizes the water content to 50-80 mass% while carefully controlling the proportions of alcohol (0-15 mass%) and glycol ether (0-20 mass%) to balance drying properties. The polymer content (5-30 mass%) is also optimized to ensure proper film formation during drying. This parameter optimization achieves reduced volatile organic compounds while maintaining acceptable drying characteristics through the coordinated action of all components.
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
The ink achieves high-resolution printing with excellent leveling properties and a reduced environmental impact by maintaining a high transfer rate and wettability, while minimizing volatile organic compounds and CO2 emissions.
Implementation Method 1
aqueous gravure inks having a less burden on the environment... failed to provide an ink having a less burden on the environment... tend to be deteriorated in wettability to a printing substrate owing to a high surface tension thereof
Implementation Method 2
the surfactant contains an acetylene glycol-based surfactant... capable of fully satisfying spreadability of the ink (hereinafter also referred to merely as 'leveling properties')
Implementation Method 3
aqueous gravure inks... content of water in the ink is not less than 50% by mass and not more than 70% by mass
Data Source
AI summary
The present invention relates to an aqueous gravure ink containing a pigment, a polymer, a water-soluble organic solvent, a surfactant and water, in which the water-soluble organic solvent contains a glycol ether having a boiling point of from 100 to 260° C., and a content of the glycol ether in the ink is from 1 to 10% by mass; a total content of the water-soluble organic solvent in the ink is not more than 15% by mass; the surfactant contains an acetylene glycol-based surfactant; and a content of water in the ink is from 50 to 70% by mass.