Foamed Printed Matter Imaging for Durable Bossed-Recessed Surfaces
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Solution Overview
Problem
Existing printed matter producing methods fail to adequately impart a bossed-recessed shape, leading to issues with design property, color developability, and durability, especially on bosses and recesses, making small-lot production difficult and prone to image damage.
Innovation Solution
A method involving a foamable layer forming step, an ink receiving layer forming step, and a foaming step, where a foamable layer containing a foaming agent is formed, followed by applying an ink with a polymerizable compound over the ink receiving layer to form an image, enhancing affinity and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If embossing with molds is used to impart bossed-recessed shape, then design property is improved, but production cost increases and manufacturing complexity increases
Solution Approach 1:
The patent replaces the mechanical embossing system (molds and pressure equipment) with a chemical foaming system. The foamable layer containing foaming agents expands when heated, automatically forming bossed-recessed shapes without requiring mechanical molds, thereby reducing production cost and manufacturing complexity while maintaining design quality
Solution Approach 2:
The patent changes the physical state and volume of the foamable layer through temperature control. By heating the material to specific temperatures, the foaming agents expand, causing the layer to increase in volume and form three-dimensional bossed-recessed structures. This parameter-based approach eliminates the need for mechanical shaping tools
2Shape
If foaming is performed before image formation, then bossed-recessed shape is created, but color development and image quality deteriorate
Solution Approach 1:
The patent applies ink to the foamable layer before the foaming process. The ink is deposited on the flat surface, and then the entire layer is heated to foam. This preliminary action ensures that the ink is properly positioned and can develop color effectively, while the subsequent foaming creates the three-dimensional shape without compromising image quality
Solution Approach 2:
The patent merges the image formation process with the foaming process by applying ink to the foamable layer before heating. Both the colorant deposition and the volume expansion occur in an integrated sequence, allowing the ink to be incorporated into the forming three-dimensional structure, thereby achieving both good color development and excellent bossed-recessed shape
3Reliability
If conventional coating methods are used, then surface protection is provided, but durability against external shocks deteriorates
Solution Approach 1:
The patent uses a composite ink composition containing colorants, binders, and polymerizable compounds that can be cured to form a durable, crosslinked protective layer. This composite material provides both color and shock resistance, eliminating the need for separate protective coating steps while enhancing durability against external shocks
Solution Approach 2:
The patent transforms the ink from a liquid state to a cured solid state through polymerization reactions initiated by heat or UV irradiation. This parameter change (from liquid to crosslinked solid) dramatically increases the durability and shock resistance of the printed layer, providing long-term protection without requiring additional manufacturing steps
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 produces printed matter with excellent design properties and image quality on bossed-recessed shapes, maintaining these qualities over time, improving color developability and durability against external shocks.
Implementation Method 1
an ink receiving layer forming step of forming an ink receiving layer containing a polymer of a polymerizable compound a
Implementation Method 2
an image forming step of applying an ink containing a colorant and a polymerizable compound b over the ink receiving layer to form an image
Implementation Method 3
a foaming step of heating the foamable layer to foam the foamable layer
Data Source
Figure 1~2
Figure 3A~3C
Figure 3D~3E
AI summary
Provided is a printed matter producing method including: a foamable layer forming step of forming a foamable layer (43) containing a foaming agent (41), an ink receiving layer forming step of forming an ink receiving layer (61) containing a polymer of a polymerizable compound a over the foamable layer (43), an image forming step of applying an ink (70) containing a colorant and a polymerizable compound b over the ink receiving layer (61) to form an image, and a foaming step of heating the foamable layer (43) to foam the foamable layer (43).