Inkjet Printing Intermediate Layer for Dot Quality and Adhesion
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Solution Overview
Problem
Inkjet printing on varied base materials like resin films, resin-impregnated paper, and wooden boards faces issues with dot image quality degradation due to coalescing and color-mixing of ink droplets, and lacks robustness due to weak adhesion between the base material and the image.
Innovation Solution
A method involving the formation of an intermediate layer to homogenize the base material's surface conditions, followed by applying an ink receiving layer with specific viscosity and surface tension properties, and using an inkjet method to form images, ensuring excellent wettability and spreadability of ink and suppressing coalescing and color-mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If inkjet printing is performed directly on varied base materials, then the process is simple and fast, but dot image quality degrades due to coalescing and color-mixing of ink droplets
Solution Approach 1:
An intermediate layer is introduced between the base material and the ink receiving layer. This intermediate layer serves as a mediator that receives ink droplets and transfers them to the ink receiving layer, preventing direct contact between ink and varied base materials. This resolves the contradiction by maintaining printing speed while preventing coalescing and color-mixing that would occur on varied surface conditions.
Solution Approach 2:
The ink receiving layer is applied to the intermediate layer before inkjet printing. This preliminary action creates a uniform, controlled surface that receives ink droplets consistently, ensuring high dot image quality while allowing rapid printing operations to proceed afterward.
2Ease of manufacture
If inkjet printing is performed on varied base materials, then the process is straightforward, but adhesion between base material and image is weak causing peeling
Solution Approach 1:
The intermediate layer acts as an adhesive mediator between the base material and the ink receiving layer. It provides a uniform bonding surface that ensures strong adhesion while maintaining process simplicity. The intermediate layer receives the ink receiving layer and transfers it to the base material, ensuring reliable attachment without complex processing.
Solution Approach 2:
The intermediate layer is formed on the base material before applying the ink receiving layer. This preliminary action creates a prepared surface that ensures strong adhesion for subsequent printing operations, preventing peeling while keeping the overall process simple and straightforward.
3Stability of the object's composition
If a uniform intermediate layer is formed over varied base materials, then surface homogeneity is improved, but the process complexity increases
Solution Approach 1:
The intermediate layer is a simple, uniform layer that mediates between varied base materials and the ink receiving layer. It provides surface homogeneity through its uniform composition and structure, while the overall process remains relatively simple by using a single intermediate layer formulation that works across different base materials.
Solution Approach 2:
The intermediate layer uses specific parameter ranges (viscosity: 40-20,000 mPa·s, surface tension: 20-60 mN/m) that are optimized to work on varied base materials. By controlling these parameters, the intermediate layer achieves surface homogeneity while maintaining process simplicity through standardized formulation.
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 results in high-definition, high-resolution images with uniform color development and improved robustness by preventing image peeling and discordance across different base materials.
Implementation Method 1
provides a dropped ink with excellent wettability and spreadability over a base material varied in surface conditions
Implementation Method 2
The viscosity of the ink receiving layer forming liquid at 25 degrees C. is 40 mPa·s or higher
Implementation Method 3
The viscosity of the ink receiving layer forming liquid at 25 degrees C. is 40 mPa·s or higher
Implementation Method 4
applying an ink to the ink receiving layer by an inkjet method to form an image
Implementation Method 5
forming an intermediate layer over a base material... to homogenize the base material's surface conditions
Data Source
AI summary
A printed matter producing method includes forming an intermediate layer over a base material; applying an ink receiving layer forming liquid to the intermediate layer to form an ink receiving layer; and applying an ink to the ink receiving layer by an inkjet method to form an image. The viscosity of the ink receiving layer forming liquid at 25 degrees C. is 40 mPa·s or higher.