Flexible Printed Material Thermal Chemical Resistance

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Solution Overview

Problem

Existing flexible printed materials are vulnerable to raised temperatures, mechanical wear, and chemicals, making them unsuitable for harsh environments such as retort or autoclave conditions.

Innovation Solution

A method involving the application of a primer layer on a flexible substrate, followed by electrostatic printing with a liquid electrostatic ink composition, and the application of a curable overprint varnish composition containing ethylenically unsaturated monomers and a cross-linking additive, which is then cured using electron beam irradiation, enhancing thermal, mechanical, and chemical resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If existing flexible printed materials are used, then they can be manufactured and applied for general purposes, but they are vulnerable to raised temperatures, mechanical wear and chemicals

Engineering Contradiction:

Improveresistance to temperature, mechanical wear and chemicalsVSAvoidvulnerability to harsh environmental conditions

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies a multi-layer composite structure consisting of a flexible substrate, primer layer, electrostatically printed ink composition layer, and curable overprint varnish composition layer. This composite structure combines materials with different properties to achieve overall resistance to temperature, mechanical wear, and chemicals that individual materials cannot provide alone.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the chemical and physical parameters of the printed material through the use of specific compositions (primer, ink, overprint varnish) and curing processes. The curable overprint varnish composition, when cured, transforms the surface properties to provide enhanced resistance to harsh conditions, effectively changing the material parameters to meet reliability requirements.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If a curable overprint varnish composition with cross-linking additive is applied and cured, then thermal, mechanical and chemical resistance is enhanced, but the process complexity increases

Engineering Contradiction:

Improvethermal, mechanical and chemical resistanceVSAvoidnumber of processing steps

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies a primer layer before the electrostatic printing process to prepare the substrate surface, ensuring proper adhesion of subsequent layers. This preliminary action prevents adhesion problems that would require complex corrective measures later, simplifying the overall process despite the multiple steps involved.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses electrostatic printing technology to apply the ink composition, replacing traditional mechanical printing methods. This substitution enables precise application of the ink layer without the mechanical complexity and potential damage associated with conventional printing presses, while maintaining the necessary layer integrity for the subsequent curing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 resulting flexible printed material exhibits improved thermal resistance, mechanical resistance, and chemical resistance, making it suitable for use in retort food pouches and other harsh conditions.

Implementation Method 1

curing the overprint varnish composition using electron beam irradiation

Methodology Applied

Scientific EffectElectron beam irradiation: Electron Beam

Implementation Method 2

curable overprint varnish composition... which is then cured using electron beam irradiation

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Implementation Method 3

electrostatically printing onto the layer of primer a liquid electrostatic ink composition

Methodology Applied

Scientific EffectElectrostatic printing: Electrostatic Deposition

Data Source

PatentUS11982974B2Flexible printed material

Publication Date: 2024.05.14 HEWLETT PACKARD DEVELOPMENT COMPANY LP

AI summary

A method of forming a flexible printed material is described. The method comprises applying a layer of primer onto a flexible substrate; electrostatically printing onto the layer of primer a liquid electrostatic ink composition; applying a curable overprint varnish composition onto the printed electrostatic ink composition and curing the overprint varnish composition using electron beam irradiation. The curable overprint varnish composition comprises an ethylenically unsaturated monomer, an ethylenically unsaturated oligomer, or mixtures thereof, and less than 10 wt. % of a cross-linking additive based on the total weight of the curable overprint varnish composition. A flexible package comprising the flexible printed material is also described.