Decorative Foil Ink-Receiving Layer for Aqueous-Ink Lamination
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Solution Overview
Problem
Existing methods for manufacturing decorative foils using digital printing on thermoplastic carriers face challenges with lamination due to the need for high-resolution small droplets, leading to ink clogging and difficulty in laminating with a wear layer, especially when using water-based inks.
Innovation Solution
A method involving a thermoplastic carrier layer with an ink receiving layer containing a binding agent, such as a hydrophilic polyurethane-based binder and silica, which enhances ink fixation and lamination strength, allowing for high-speed single-pass digital printing without the need for an additional adhesion layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If digital printing with small droplets is used to achieve high resolution, then printing quality is improved, but inkjet nozzle clogging occurs and lamination becomes difficult
Solution Approach 1:
An ink receiving layer is introduced as an intermediary between the thermoplastic carrier layer and the aqueous ink. This layer contains hydrophilic binding agents (such as polyvinyl alcohol, carboxymethyl cellulose, or starch) that selectively absorb and retain the aqueous ink, preventing it from penetrating into the carrier layer. The ink receiving layer acts as a buffer that facilitates ink transfer while maintaining lamination compatibility, thereby resolving the contradiction between high-resolution printing and lamination reliability.
2Productivity
If water-based inks are used for digital printing, then printing speed and productivity are improved, but lamination with wear layer becomes difficult
Solution Approach 1:
The ink receiving layer serves as a mediator between the water-based ink and the thermoplastic carrier layer. It contains hydrophilic binding agents that retain the aqueous ink through capillary action and hydrogen bonding, preventing water from interfering with the subsequent lamination process. This allows high-speed digital printing with water-based inks while maintaining ease of lamination with wear layers, as the ink receiving layer controls ink release during lamination.
Solution Approach 2:
The invention changes the physical and chemical parameters of the carrier layer surface by adding an ink receiving layer with specific properties: hydrophilic binding agents with controlled molecular weight, specific pigment-to-binder ratios, and optimized layer thickness. These parameter changes enable the carrier layer to accept water-based inks at high speeds while maintaining compatibility with thermoplastic lamination processes.
3Strength
If additional adhesion layer is added to improve lamination, then lamination strength is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The invention merges multiple functions into the ink receiving layer: it serves as both the ink retention layer and the adhesion promoter for lamination. The hydrophilic binding agents in this layer provide both ink binding capability and lamination adhesion, eliminating the need for a separate adhesion layer. This reduces structural complexity while maintaining lamination strength, as the ink receiving layer performs dual functions of ink management and bond promotion.
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 method achieves lamination strengths of over 50N per 5 cm, suitable for industrial use, and maintains high printing quality and throughput speed, reducing dustiness and improving lamination with a transparent wear layer.
Implementation Method 1
the ink receiving layer comprises a binding agent, preferably different from an acrylic copolymer, and/or silica
Implementation Method 2
The binding agent is preferably hydrophilic such that it can cope with the water content of the aqueous ink
Implementation Method 3
The binding agent is preferably hydrophilic such that it can cope with the water content of the aqueous ink
Implementation Method 4
the binding agent is also active in a subsequent lamination of the obtained decorative foil with e.g. a transparent wear layer
Data Source
AI summary
A method for manufacturing a decorative foil may involve providing a thermoplastic carrier layer. An ink receiving layer may be provided to the carrier layer. A decorative pattern may be formed on the carrier layer by performing a digital printing operation wherein droplets of aqueous inks having a volume smaller than 100 pL are jet to the ink receiving layer. The ink receiving layer may include a binding agent.