Film Production Viscosity and Temperature Control

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Solution Overview

Problem

The production of films using compositions with pigments, resins, and solvents often results in low stability, leading to sedimentation of pigments and coating unevenness, particularly with high-density inorganic pigments like white pigments.

Innovation Solution

A method involving preserving the composition at a viscosity range of 30 mPa·s to 150 mPa·s and heating it to 40° C to 70° C during application, while maintaining a sedimentation rate of solid content at 10% or less, to enhance coatability and prevent coating unevenness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a composition including high-density inorganic pigment is used, then the film can be produced with desired optical properties, but the pigment is easily sedimented and coatability is reduced

Engineering Contradiction:

Improvestability of compositionVSAvoidcoatability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent applies parameter changes by controlling the viscosity of the composition within a specific range (30-150 mPa·s) and maintaining the sedimentation rate of solid content at 10% or less. These parameter optimizations resolve the contradiction by adjusting physical properties to achieve both stability and coatability simultaneously

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If the composition is preserved without viscosity control, then the storage is simpler, but the pigment sedimentation occurs and coating unevenness is caused

Engineering Contradiction:

Improvesimplicity of preservationVSAvoidcoating uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent specifies maintaining viscosity within 30-150 mPa·s and sedimentation rate at 10% or less to prevent coating unevenness while preserving the composition. These controlled parameter ranges enable both simple preservation and high coating precision

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If the viscosity of the composition is too low, then the application is easier, but the pigment sedimentation increases and stability is reduced

Engineering Contradiction:

Improveease of applicationVSAvoidstability of composition

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent identifies an optimal viscosity range of 30-150 mPa·s that balances ease of application with prevention of pigment sedimentation. This parameter optimization resolves the contradiction by finding the sweet spot where both operability and stability are achieved

Inventive Principle:

Principle #35Parameter changes

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 approach effectively suppresses coating unevenness and improves coatability, especially when using high-density inorganic pigments, by maintaining the composition's fluidity and preventing pigment sedimentation.

Implementation Method 1

heating the composition to 40° C. to 70° C. so as to be applied during the application of the composition

Methodology Applied

Scientific EffectViscosity reduction through heating: Heating

Implementation Method 2

preserving a composition including a pigment, a resin, and a solvent under a condition of a viscosity ranging from 30 mPa·s to 150 mPa·s

Methodology Applied

Scientific EffectSedimentation prevention through viscosity control: Sedimentation

Data Source

PatentUS11045834B2Method for producing film

Publication Date: 2021.06.29 FUJIFILM CORP

AI summary

A method for producing a film comprises preserving a composition including a pigment, a resin, and a solvent under a condition of a viscosity ranging from 30 mPa·s to 150 mPa·s, and heating the composition to 40° C. to 70° C. so as to be applied during the application of the composition.