Foaming Agent Layer for Durable Printed Surfaces
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Solution Overview
Problem
Existing methods for enhancing the durability and designability of printed materials, such as flooring and wallpaper, fail to achieve excellent rough surface forms and image quality, particularly when using ultraviolet curing or electron beam curing materials, and chemical embossing methods do not effectively create uneven surfaces with sufficient design properties.
Innovation Solution
A printing method involving the application of a foaming agent composition followed by a foaming inhibitor composition, where the foaming agent composition has a viscosity of 50 to 1,500 mPa·s and a static surface tension difference of 5 mN/m or less with the inhibitor, allowing for controlled foaming and surface roughness through active energy curing and heating, enabling the formation of robust and durable uneven surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultraviolet curing material or electron beam curing material is used to enhance durability, then durability is improved, but the ability to create excellent rough surface forms and image quality deteriorates
Solution Approach 1:
The invention divides the coating system into multiple functional layers: a base layer containing ultraviolet curing material for durability, and a foaming agent layer that creates the rough surface pattern. This segmentation allows each layer to perform its specific function without interfering with the other, resolving the contradiction between durability and surface quality.
Solution Approach 2:
The foaming agent layer is applied locally to specific regions where rough surface forms are desired, while the ultraviolet curing material provides overall durability. This local application of different properties allows the material to simultaneously achieve both durability in covered areas and excellent rough surface forms in foamed regions.
2Adaptability or versatility
If chemical embossing using aqueous resin is used to create uneven surfaces, then designing property is improved, but image quality and durability deteriorate
Solution Approach 1:
The invention changes the chemical parameters of the embossing agent from aqueous resin to a foaming agent composition with specific viscosity (50-1,500 mPa·s) and surface tension (within 5 mN/m of the inhibitor). These parameter changes enable the embossing agent to create excellent rough surface forms while the subsequent ultraviolet curing provides durability, thus resolving the contradiction between designing property and durability.
3Ease of operation
If foaming agent composition with inappropriate viscosity or surface tension is used, then application is simplified, but the ability to create clear height differences and maintain designing property deteriorates
Solution Approach 1:
The invention specifies optimal parameter ranges for the foaming agent composition: viscosity of 50-1,500 mPa·s and surface tension within 5 mN/m of the foaming inhibitor composition. These parameter changes ensure proper flow and leveling during application while maintaining the ability to create clear height differences and excellent rough surface forms after foaming.
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 designing properties and image quality due to its ability to create clear height differences and maintain these properties over time, providing enhanced durability and chemical resistance.
Implementation Method 1
curing the foaming agent layer with irradiation of active energy
Implementation Method 2
heating the foaming agent layer to foam the foaming agent layer
Implementation Method 3
heating the foaming agent layer to foam the foaming agent layer
Data Source
Figure 1~2
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AI summary
A printing method includes applying a foaming agent composition containing a foaming agent to form a foaming agent layer, applying a foaming inhibitor composition containing a foaming inhibitor onto the foaming agent layer, curing the foaming agent layer with irradiation of active energy, and heating the foaming agent layer to foam the foaming agent layer, wherein the foaming agent composition has a viscosity of from 50 to 1,500 mPa·s at 25 degrees C and the absolute difference between the static surface tension of the foaming agent composition and the static surface tension of the foaming inhibitor composition is 5 mN/m or less.