Composite Polymeric Material for Inherently Printable Thermoformed Films
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Solution Overview
Problem
Conventional polymeric films require printing receptive layers or treatments to achieve printability, which can diminish over time and during thermoforming, necessitating repeated treatments and specialized equipment, increasing costs and complexity.
Innovation Solution
A composite polymeric material comprising a blend of thermoplastic polymer, cyclic olefin copolymer, ionomer of ethylene and methacrylic acid, and thermoplastic rubber, which does not require surface treatments to maintain printability, even after thermoforming and exposure to moisture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional polymeric films are used, then the material has low cost and simple composition, but the film requires printing receptive layers or treatments to achieve printability
Solution Approach 1:
The patent modifies the chemical composition parameters of the polymeric film by incorporating specific functional groups (carboxylic acid, hydroxyl, amine groups) and blending multiple polymers in defined ratios. This changes the surface energy and chemical reactivity parameters of the film, enabling direct ink adhesion without additional treatments.
Solution Approach 2:
The patent creates a composite polymeric material blending at least two different polymers with complementary properties. One polymer provides structural integrity while the other provides surface functionality for ink adhesion. This composite structure inherently provides both printability and durability without requiring separate treatment layers.
2Ease of manufacture
If surface treatments are applied to conventional films, then printability is improved, but the treatment effects diminish over time and after thermoforming
Solution Approach 1:
The patent incorporates print-receptive functional groups directly into the polymer structure during the film manufacturing process. This preliminary incorporation ensures that the printability function is built-in from the start and remains stable throughout the film's lifecycle, including after thermoforming and extended storage periods.
Solution Approach 2:
The patent selects polymers with specific glass transition temperatures (Tg) and chemical compositions that maintain their surface properties across a wide temperature range. This ensures the print-receptive characteristics remain stable during thermoforming (heating) and cooling cycles, preventing loss of printability over time.
3Ease of manufacture
If repeated surface treatments are applied, then printability is maintained, but costs increase and specialized equipment is required
Solution Approach 1:
The patent designs the polymeric film to be self-receptive to printing without requiring external treatment processes. The inherent chemical functionality of the film surface enables direct ink adhesion, eliminating the need for corona discharge, plasma treatment, or flame treatment equipment and associated operational costs.
Solution Approach 2:
The patent optimizes the polymer blend composition and functional group concentration to achieve optimal printability at the film manufacturing stage. This single-step incorporation during extrusion eliminates the need for subsequent treatment steps, reducing both equipment requirements and production costs.
4Reliability
If polyolefin films are used, then the material has good chemical inertness and durability, but the films are almost untreatable after production
Solution Approach 1:
The patent creates a composite where chemically inert polyolefin provides structural durability and barrier properties, while blended polymers with reactive functional groups (carboxylic acid, hydroxyl, amine) provide surface printability. This composite structure combines the advantages of both material types without compromising either durability or printability.
Solution Approach 2:
The patent concentrates print-receptive functional groups at the film surface through careful polymer selection and blending ratios, while the bulk material maintains the chemical inertness and durability of polyolefin. This local differentiation allows the surface to be highly reactive to ink while the bulk remains chemically stable and durable.
Data Source
AI summary
An inherently printable polymeric material is provided. The polymeric material includes a homogenous mixture of a thermoplastic polymer with a Tg of about 30-80°C, a cyclic olefin copolymer, an ionomer of ethylene and methacrylic acid, and a thermoplastic rubber. The polymeric material can be printed without requiring printing receptive layers or treatments. The polymeric material can be thermoformed, yet retains its printability even after thermoforming.