De-contented Ink Printing on Plastic Substrates
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Solution Overview
Problem
Current methods for printing on plastic substrates using non-polar, water insoluble, high molecular weight latex binders result in limited print speeds, VOC issues, and nozzle blockage due to insoluble crust formation, while de-contented ink lacks durability as it lacks binders to adhere pigments effectively.
Innovation Solution
A system that uses de-contented ink, where the ink film is heated to a temperature just below the plastic substrate's melting point, allowing particles to diffuse into the substrate, and optionally employs a primer for substrates with high melting temperatures, utilizing an LED-based energy source for precise and targeted heating to create a durable image.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If non-polar, water insoluble, high molecular weight latex binders are used to print on plastic substrates, then image durability is improved, but print speed is limited and VOC emissions increase due to co-solvent evaporation and high-temperature fusion requirements
Solution Approach 1:
The patent extracts and removes the binder component from the ink formulation, creating a de-contented ink that contains only pigment particles suspended in water. This eliminates the need for co-solvents and high-temperature fusion processes, thereby improving print speed and reducing VOC emissions while maintaining image durability through alternative adhesion mechanisms
Solution Approach 2:
The patent changes the physical and chemical parameters of the ink system by transitioning from a binder-based formulation to a binder-free de-contented ink. This parameter change allows the ink to be jetted at lower temperatures and eliminates the need for high-temperature fusion, thus improving print speed and reducing VOC emissions while achieving durable images through particle diffusion into the substrate
2Strength
If non-polar, water insoluble, high molecular weight latex binders are used to print on plastic substrates, then image durability is improved, but VOC emissions increase due to co-solvent evaporation and high-temperature fusion
Solution Approach 1:
The patent extracts and removes the binder component from the ink formulation, creating a de-contented ink that contains only pigment particles suspended in water. This eliminates the need for co-solvents and high-temperature fusion processes, thereby improving print speed and reducing VOC emissions while maintaining image durability through alternative adhesion mechanisms
Solution Approach 2:
The patent uses water as a temporary, environmentally benign carrier that evaporates completely without leaving harmful residues. The water-based suspension allows for easy jetting and complete evaporation, eliminating VOC emissions from co-solvents while the pigment particles remain adhered to the substrate through diffusion and capillary forces
3Strength
If non-polar, water insoluble, high molecular weight latex binders are used, then image durability is improved, but nozzle blockage occurs due to insoluble crust formation
Solution Approach 1:
The patent extracts and removes the binder component from the ink formulation, creating a de-contented ink that contains only pigment particles suspended in water. This eliminates the need for co-solvents and high-temperature fusion processes, thereby improving print speed and reducing VOC emissions while maintaining image durability through alternative adhesion mechanisms
Solution Approach 2:
The patent changes the physical and chemical parameters of the ink system by transitioning from a binder-based formulation to a binder-free de-contented ink. This parameter change allows the ink to be jetted at lower temperatures and eliminates the need for high-temperature fusion, thus improving print speed and reducing VOC emissions while achieving durable images through particle diffusion into the substrate
4Productivity
If de-contented ink is used to print on plastic substrates, then print speed and VOC emissions are improved, but image durability decreases due to lack of binder for pigment adhesion
Solution Approach 1:
The patent replaces the chemical adhesion mechanism (binder holding pigment particles) with a physical diffusion mechanism. The pigment particles are driven into the plastic substrate through thermal energy and capillary forces, eliminating the need for chemical binders while achieving durable image attachment
Solution Approach 2:
The patent utilizes phase transitions of the plastic substrate (heating to near melting point) to enable pigment particle diffusion into the substrate. This phase transition approach allows de-contented ink particles to be embedded in the substrate matrix, achieving durable adhesion without requiring organic binders
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
This method produces durable images on plastic substrates that withstand eraser rubs, liquid wipes, and tape adhesion, while maintaining low VOC emissions and improving print speed by ensuring reliable jetting and adhesion without the need for high-temperature fusion.
Implementation Method 1
the ink film is heated to a temperature just below the plastic substrate's melting point, allowing particles to diffuse into the substrate
Implementation Method 2
utilizing an LED-based energy source for precise and targeted heating
Data Source
AI summary
In example implementations, a system is provided. The system includes at least one fluid ejection apparatus, a heater and an energy source. The at least one fluid ejection apparatus dispenses a de-contented fluid onto a substrate during conveyance of the substrate. The heater is arranged after the at least one fluid ejection apparatus along a substrate conveying path. The heater removes a liquid from the de-contented fluid on the substrate such that the particles of the de-contented fluid remain on the substrate. The energy source is arranged after the heater along the substrate conveying path. The energy source applies energy to the substrate during the conveyance of the substrate to heat the substrate to a temperature that is approximately a melting temperature of the substrate to fuse the particles on the substrate to the substrate.