Ink Receiving Layer Surface Roughness for UV Curing Stability
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Solution Overview
Problem
Ink jet printing on building materials using active ray-curable inks faces challenges with uneven color development and durability due to rapid wet spread and permeability issues, especially when cured immediately after application, leading to instability in image quality and susceptibility to water damage.
Innovation Solution
A method involving the formation of an ink receiving layer with specific irregularities on metallic or ceramic base materials, using an active ray-curable ink that is irradiated within a controlled time frame of 2.2 to 30 seconds after application, ensuring stable wet spread and enhanced durability through the use of a non-permeable ink receiving layer with adjusted roughness and polymer compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If active ray-curable ink is cured immediately after application (within 1 second), then curing speed is improved, but ink wet spread is unstable causing uneven color development
Solution Approach 1:
The ink receiving layer is prepared in advance with specific surface roughness (0.4-3 μm) and non-permeable properties to control ink wet spread before curing occurs. This preliminary preparation ensures that when ink is applied and cured within 2.2-30 seconds, the wet spread is stabilized and color development becomes uniform.
Solution Approach 2:
The patent changes the physical parameters of the ink receiving layer by controlling its surface roughness to 0.4-3 μm and ensuring non-permeability. These parameter changes enable the ink to spread stably during the curing period of 2.2-30 seconds, resolving the contradiction between fast curing and uniform color development.
2Quantity of substance
If porous ink receiving layer is used for aqueous ink, then ink absorption is improved, but water permeability causes durability issues against rain and water damage
Solution Approach 1:
The patent uses a non-permeable ink receiving layer with controlled surface roughness (0.4-3 μm) that prevents water penetration while still allowing ink to be absorbed and cured. This eliminates the durability issues associated with porous layers while maintaining ink absorption capabilities.
Solution Approach 2:
The ink receiving layer is formed as a composite structure with specific surface properties (roughness 0.4-3 μm) that combine ink absorption functionality with water resistance. This composite approach enables the layer to absorb ink effectively while preventing water penetration, ensuring long-term durability.
3Ease of manufacture
If flat surface is used for recording material, then manufacturing simplicity is improved, but ink wet spread is insufficient even with regulated time period
Solution Approach 1:
The patent changes the surface parameter from flat to controlled roughness (0.4-3 μm), which enhances ink wet spread stability. This parameter modification allows ink to spread uniformly during the curing period without requiring complex surface preparation processes.
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 approach enables high designability and weather-resistant, water-resistant patterns on building boards by stabilizing ink spread and curing, thereby improving image quality and durability against environmental factors.
Implementation Method 1
irradiating the active ray-curable ink with an active ray within 2.2 seconds or more and 30 seconds or less after the active ray-curable ink lands on the ink receiving layer
Implementation Method 2
When the ink lands on the ink receiving layer of the recording material, the ink rapidly spreads with wetting (within 0.5 second) due to capillary action
Data Source
AI summary
The present invention relates to a method of manufacturing a decorative building board, including: ejecting active ray-curable ink from an ink jet recording head onto a building board that includes a base material selected from a metallic base material and a ceramic base material and an ink receiving layer arranged on the base material, the ink receiving layer being obtained by curing a resin composition and having an arithmetic average roughness (Ra) specified under JIS B 0601:2001 of from 0.4 μm to 3 μm, to thereby perform printing on the ink receiving layer; and irradiating the active ray-curable ink with an active ray from 2.2 seconds to 30 seconds after the active ray-curable ink lands on the ink receiving layer.