Laminates Using Transparent Electrostatic Ink for Bond Strength

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Solution Overview

Problem

Existing laminates, particularly in blister packs, face challenges with delamination due to insufficient bond strength, which affects their structural integrity and durability.

Innovation Solution

A laminate structure is developed using a transparent electrostatic ink composition comprising a thermoplastic resin and a charge adjuvant or charge director, which is selectively printed onto a base material and adheres a substrate, enhancing the bond strength between layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional adhesive methods are used to bond laminate layers, then the bonding process is simple and cost-effective, but the bond strength is insufficient leading to delamination

Engineering Contradiction:

Improvebond strengthVSAvoidprocess complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent introduces an electrostatic ink composition as an intermediary substance between the base material and substrate. This composition contains thermoplastic resin particles that, when heated, melt and form strong adhesive bonds. The intermediary layer enables strong bonding without requiring complex adhesive application systems, resolving the contradiction between bond strength and process complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent utilizes temperature parameter changes to transform the bonding process. The electrostatic ink composition is applied at room temperature and then heated to melt the thermoplastic resin particles, creating strong bonds. This parameter change approach allows simple application processes while achieving high bond strength through controlled thermal transformation.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If traditional lamination processes are used, then the manufacturing process is straightforward, but the laminate suffers from delamination and poor structural integrity

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical adhesive application systems with an electrostatic deposition system. The electrostatic ink composition is deposited using electrostatic forces, and the thermoplastic resin particles are subsequently melted through heating. This substitution maintains manufacturing simplicity while dramatically improving structural integrity and preventing delamination.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs a composite bonding system consisting of electrostatic ink composition with thermoplastic resin particles embedded in a carrier liquid. This composite material provides both the ease of liquid application and the strength of thermoplastic bonding when melted, achieving high reliability without complicating the manufacturing process.

Inventive Principle:

Principle #40Composite materials

3Duration of action of stationary object

If adhesive layers are applied between laminate layers, then bonding can be achieved, but the additional layers increase the risk of delamination and reduce durability

Engineering Contradiction:

ImprovedurabilityVSAvoidlaminate structure complexity

Core Design Contradiction:

Duration of action of stationary objectVSDevice complexity

Solution Approach 1:

The patent merges the adhesive function with the electrostatic ink layer itself. The thermoplastic resin particles in the electrostatic ink composition serve dual purposes: forming the visible print layer and providing the bonding adhesive when melted. This consolidation eliminates the need for separate adhesive layers, reducing structural complexity while enhancing durability and preventing delamination.

Inventive Principle:

Principle #5Merging (Combining)

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 solution achieves a significant increase in lamination bond strength, ensuring the laminate's integrity and reducing the risk of delamination, as measured by ASTM F0904-98R08 standards, with bond strengths ranging from 0.5 to 10 N/inch.

Implementation Method 1

a substrate adhered to the base material at the portion of the base material by the transparent electrostatic ink composition

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

transparent electrostatic ink composition selectively disposed on a portion of the base material

Methodology Applied

Scientific EffectElectrostatic deposition: Electrostatic Deposition

Data Source

PatentUS10562268B2Laminates

Publication Date: 2020.02.18 HP INDIGO BV

AI summary

There is provided a laminate, comprising a base material, a transparent electrostatic ink composition selectively disposed on portions of the base material, the transparent electrostatic ink composition comprising a thermoplastic resin, and a charge adjuvant and/or a charge director; a substrate adhered to the base material at the portions of the base material by the transparent electrostatic ink composition. A process for preparing a laminate and a blister pack are also disclosed.