Ink Formulation for High-Resolution Molded Part Printing
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Solution Overview
Problem
Existing processes for obtaining composite skins with colored parts, such as in mold painting and in mold coating, struggle to achieve high quality printed surfaces, particularly when creating fine patterns or detailed shapes due to the rheological properties of the colored compositions, which limit printing precision.
Innovation Solution
A composition comprising 5-20% thermoplastic resin, 1-20% modifying agents, 5-20% plasticizer, and 45-75% organic solvent, with a viscosity of 5-40 mPa.s, allowing for precise projection through small diameter nozzles to achieve high quality printed surfaces, including fine lines and dotted patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If colored compositions with large orifice paint guns are used for in mold painting, then the printing process can be implemented, but the printing precision is reduced and fine lines cannot be created
Solution Approach 1:
The patent changes the rheological parameters of the colored composition by adjusting viscosity (to 5-40 mPa.s at 20°C), particle size distribution (0.1-10 μm thermoplastic resin particles), and composition ratios (plasticizer 5-20%, modifying agents 1-20%). These parameter changes enable the composition to be projected through small diameter nozzles (20-40 μm) while maintaining printability and achieving high printing precision including fine lines and dotted patterns.
2Manufacturing precision
If small diameter nozzles are used for projection, then printing precision improves, but the rheological properties of existing colored compositions prevent their use
Solution Approach 1:
The patent modifies the rheological properties by controlling viscosity within 5-40 mPa.s at 20°C, adjusting solid particle content (15-30% thermoplastic resin particles), and optimizing the plasticizer-to-resin ratio (0.5:1 to 2:1). These parameter adjustments ensure the composition remains flowable enough for small nozzle projection while maintaining structural integrity and printability.
Solution Approach 2:
The colored composition is formulated as a composite material containing thermoplastic resin particles (0.1-10 μm), plasticizer (5-20%), modifying agents (1-20%), and solvent (45-75%). This composite structure provides both the flow characteristics needed for small nozzle projection and the structural properties required for reliable printing and pattern formation.
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
Enables the production of molded objects with high quality printed surfaces, specifically allowing for 360 or 720 dpi prints in one or two passes, and enhances the resistance of the resin to abrasion.
Implementation Method 1
The composition has a viscosity preferably between 5 and 40 mPa.s and even more preferably between 10 and 25 mPa.s at 20°C, measured with a BROOKFIELD® type viscometer. This viscosity range enables projection through small diameter printing nozzles while maintaining printability.
Implementation Method 2
The composition comprises 5 to 20% of at least one thermoplastic resin whose particles have a size between 0.1 and 10 μm. Heating the mold causes these particles to melt and fuse, forming a solid colored printed surface.
Data Source
AI summary
The present invention relates to a method for obtaining a molded object made of laminated thermoplastic resin, said object having a high-quality printed surface. The present invention also relates to the resulting molded objects and to an ink specially suited for use in the above-mentioned method.