Ink Jet Printing Polymerization Control for Lamination Adhesion
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Solution Overview
Problem
Existing methods for producing printed matter fail to simultaneously improve laminate adhesion and image quality, often resulting in poor adhesion leading to peeling issues and decreased image quality.
Innovation Solution
A method involving ink jet printing with active ray-curable ink, followed by partial polymerization in the first active ray irradiation step, lamination with an adhesive layer, and further polymerization in the second active ray irradiation step, which enhances laminate adhesion and image durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ink is completely cured before lamination, then the image quality is maintained, but the laminate adhesion deteriorates
Solution Approach 1:
The patent applies preliminary action by performing the first active ray irradiation step before lamination to partially polymerize the photopolymerizable compound (5-80% polymerization rate). This partial curing creates a surface that promotes adhesive layer bonding while preserving image quality, resolving the contradiction between laminate adhesion and image quality maintenance.
Solution Approach 2:
The patent changes the polymerization rate parameter by controlling the first active ray irradiation to achieve 5-80% polymerization rather than complete curing. This parameter adjustment allows the ink layer to have both sufficient adhesion for lamination and sufficient uncured portions to maintain image quality, solving the technical contradiction.
2Reliability
If the ink is not completely cured before lamination, then the laminate adhesion improves, but the image quality deteriorates
Solution Approach 1:
The patent performs preliminary polymerization (5-80% rate) through the first active ray irradiation step before lamination. This controlled partial curing creates optimal surface properties for adhesive bonding while preserving enough uncured material to maintain image quality, resolving the contradiction in favor of both adhesion and image quality.
Solution Approach 2:
By precisely controlling the polymerization rate parameter to 5-80% through controlled active ray irradiation, the patent achieves a state where both laminate adhesion and image quality are optimized, eliminating the need to choose one over the other.
3Reliability
If a single active ray irradiation step is used, then the process is simple, but both laminate adhesion and image quality cannot be simultaneously improved
Solution Approach 1:
The patent segments the active ray irradiation process into two distinct steps: a first irradiation step before lamination for partial polymerization (5-80%), and a second irradiation step after lamination for complete polymerization. This segmentation allows each step to serve a specific function, achieving both laminate adhesion and image quality improvement without excessive complexity.
Solution Approach 2:
The first active ray irradiation step performs preliminary polymerization before lamination, creating optimal surface conditions for adhesive bonding. The second step completes the polymerization after lamination to ensure image quality. This sequential approach resolves the contradiction by dividing the complex task into manageable stages.
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
This method effectively improves both laminate adhesion and image quality, preventing dot collapse and ensuring strong mechanical bonds, thereby enhancing the durability of the printed matter.
Implementation Method 1
a first active ray irradiation step of irradiating the printing layer with an active ray to bring a rate of polymerization of a photopolymerizable compound of the ink that constitutes the printing layer to a range of 5% to 80%
Data Source
Figure 1A~1D
AI summary
A method for producing printed matter, including: a print step of forming a printing layer 2 on a non-absorbent or slightly absorbent base material 1 by ink jet printing using an ink that is active ray-curable; a first active ray irradiation step of irradiating the printing layer 2 with an active ray to bring a rate of polymerization of a photopolymerizable compound of the ink that constitutes the printing layer 2 to a range of 5% to 80%; a lamination step of laminating a laminate film 4 on the printing layer 2 with an adhesive layer 3 interposed between the laminate film 4 and the printing layer 2; and a second active ray irradiation step of irradiating the printing layer 2 with an active ray from the laminate film 4 side or the non-absorbent or slightly absorbent base material 1 side to further increase the rate of polymerization of a photopolymerizable compound of the ink that constitutes the printing layer 2.