Composite Printable Media with Textured Image Layer
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Solution Overview
Problem
Existing large format printing technologies face challenges in producing durable, environmentally friendly, and high-quality prints on substrates like wall coverings and banners, particularly in terms of ink adhesion, durability, and compliance with environmental standards, due to the limitations of current media substrates.
Innovation Solution
A composite printable media with a multi-layer structure comprising a fiber layer, a fabric layer, and a flame-resistant adhesion layer, combined with an image receiving layer featuring textured surfaces, designed to support inkjet printing and meet stringent durability and environmental standards, such as ASTM F793 and CCC-W-408A, while avoiding harmful materials like PVC.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional substrates are used for large format printing, then printing cost is reduced, but ink adhesion and image durability are insufficient
Solution Approach 1:
The substrate is divided into multiple functional layers: a base layer providing structural support, an intermediate layer enhancing ink adhesion, and a surface layer optimizing image quality. This segmentation allows each layer to specialize in specific functions, improving overall ink adhesion and durability without using complex external components
Solution Approach 2:
The patent employs composite material construction by combining different materials with complementary properties in a multi-layer substrate structure. The base layer may use rigid materials for stability, while intermediate and surface layers use materials optimized for ink absorption and image retention, creating a composite system that achieves superior ink adhesion and image durability
2Ease of manufacture
If PVC-containing materials are used in substrates, then manufacturing ease is improved, but environmental compliance deteriorates
Solution Approach 1:
The invention removes harmful PVC components from the substrate composition entirely, extracting the problematic element while retaining the essential functional requirements. The substrate is reformulated using environmentally benign materials that provide equivalent or superior performance without the harmful effects of PVC
Solution Approach 2:
The patent changes the material composition parameters by substituting PVC with alternative materials that have different chemical and physical properties. This parameter change eliminates environmental harm while maintaining manufacturability through adjusted formulation and processing parameters suitable for the new materials
3Reliability
If smooth surfaces are used for printing, then manufacturing precision is improved, but ink adhesion and image quality deteriorate
Solution Approach 1:
The substrate implements local quality differentiation by providing smooth regions for dimensional stability and controlled regions with enhanced surface characteristics for ink adhesion. Different areas or layers of the substrate have optimized properties: some regions maintain flatness for manufacturing precision, while other regions provide increased surface area or chemical affinity for better ink bonding and image quality
Data Source
AI summary
A printable media comprising a composite supporting substrate, having an image side and a non-image side, that contains a first and a second constituent material layers wherein, at least, one of the constituent material layer is a fiber layer and wherein the first and the second materials layers are laminated together with a flame resistant adhesion layer. The printable media further comprises an image receiving layer that is coated on the second layer on the image side of the composite supporting substrate. In the printable media described herein, at least, the image side of the composite supporting substrate and the image receiving layer are textured surfaces. Also disclosed is a method for producing the textured media.