High-Yield Paper Ink Jet Printing Porosity Control
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Solution Overview
Problem
Current low basis weight papers are not suitable for high-speed ink jet printing due to issues like ink bleeding and cockling, resulting in poor image quality, necessitating a paper specifically designed for high-yield, low porosity, and desirable ink interactions.
Innovation Solution
A high-yield paper sheet made with at least 50% mechanical pulp, having a basis weight of 24 to 60 pounds and porosity of 40 to 100 Sheffield, with a surface layer containing nano precipitated calcium carbonate (nPCC) to improve stiffness, color gamut, and ink density, and using specific machine conditions for production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If low basis weight paper (newsprint grade) is used to reduce costs, then paper cost and postage cost are reduced, but ink bleeding and cockling occur resulting in poor image quality
Solution Approach 1:
The patent applies parameter changes by precisely controlling porosity (40-100 Sheffield) and basis weight (24-60 pounds) to achieve optimal ink jet printing performance. This resolves the contradiction by finding the specific parameter range where low basis weight does not compromise image quality, unlike conventional newsprint
Solution Approach 2:
The patent uses composite materials by combining mechanical pulp (at least 50% of total pulp) with specific additives and treatments to create a paper structure that maintains low basis weight while preventing ink bleeding and cockling. The composite structure achieves both cost reduction and image quality
2Productivity
If high-speed ink jet printing is implemented to increase productivity, then printing speed and cost per page are improved, but paper quality requirements become more stringent
Solution Approach 1:
The patent specifies precise parameter ranges (porosity: 40-100 Sheffield, basis weight: 24-60 pounds, mechanical pulp content: at least 50%) to ensure paper quality consistency required for high-speed ink jet printing. These controlled parameters enable both high productivity and manufacturing precision
3Productivity
If mechanical pulp content is increased to at least 50% to achieve high yield, then production efficiency and cost are improved, but paper porosity and ink interaction become harder to control
Solution Approach 1:
The patent resolves this contradiction by establishing a specific porosity range (40-100 Sheffield) that works effectively with high mechanical pulp content (at least 50%). This parameter control enables both high production yield and precise porosity management for optimal ink jet printing
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 results in a paper that supports good ink and paper interactions, enhanced stiffness, and improved image quality for high-speed ink jet printing, reducing costs and waste while maintaining high yield and low porosity.
Implementation Method 1
a surface layer containing nano precipitated calcium carbonate (nPCC) to improve stiffness
Implementation Method 2
a surface layer containing nano precipitated calcium carbonate (nPCC) to improve stiffness, color gamut, and ink density
Implementation Method 3
the porosity of the sheet is in the range of about 40 to about 100 Sheffield porosity
Data Source
AI summary
A high-yield paper sheet generally includes at least about 50 weight percent mechanical pulp, wherein the basis weight of the sheet is in the range of about 24 to about 60 pounds, and wherein the porosity of the sheet is in the range of about 40 to about 100 Sheffield porosity.