Laminated Cured Film Elongation via Segmented Dot Patterns
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Solution Overview
Problem
Existing image forming methods on plastic bases face a trade-off between elongation and density, where thick cured films lose elongability and clear colors when elongated, and previous solutions either compromise on density or productivity.
Innovation Solution
An image forming method involving a two-step process where liquid droplets of active-energy-ray-curable ink are discharged and irradiated to form a laminated cured product with a dot pattern on the base, achieving an elongation rate of 60% or greater by maintaining a high film thickness and density through specific dot pattern arrangements and ink compositions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a thick cured film is formed on the plastic base to achieve high density and clear colors, then the image density and color clarity are improved, but the elongability of the cured film deteriorates
Solution Approach 1:
The cured film is divided into multiple independent dot patterns arranged in a matrix. Each dot acts as an independent unit that can deform individually during elongation, preventing the entire thick film from cracking while maintaining high density through the collective arrangement of dots.
Solution Approach 2:
The dot pattern creates local variations in film structure where each dot maintains high thickness for density while the spaces between dots provide flexibility. This local differentiation allows different regions to serve different functions: dots for density and inter-dot regions for elongation accommodation.
2Manufacturing precision
If a thick cured film is formed to maintain density after elongation, then the image density is improved, but the film becomes more rigid and harder to process
Solution Approach 1:
By segmenting the thick film into discrete dot patterns, the overall structure gains flexibility despite local thickness. The segmented dots can shift and deform independently during handling and elongation processes, improving workability while each dot maintains sufficient thickness for density.
3Length of stationary object
If the cured film is made thick to prevent thinning during elongation, then the film thickness is maintained, but the elongation rate decreases
Solution Approach 1:
The film is segmented into dots that can individually accommodate elongation through deformation and spacing changes. This allows the overall film to achieve high elongation rates while each dot maintains its thickness, preventing the thinning that occurs in continuous thick films during stretching.
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 method successfully maintains high elongability and density of the laminated cured product, allowing it to be elongated significantly without losing film thickness, thereby overcoming the trade-off limitations of previous techniques.
Implementation Method 1
irradiating the liquid-droplet film with an active energy ray to form a cured film
Data Source
AI summary
Provided is an image forming method including an image forming step of discharging liquid droplets of an active-energy-ray-curable ink onto a base to form a liquid-droplet film and irradiating the liquid-droplet film with an active energy ray to form a cured film, to form a laminated cured product in which the cured film is laminated on the base, wherein an elongation rate of the laminated cured product obtained according to a formula below is 60 percent or greater.Elongation rate=[(length after tensile test−length before tensile test)/(length before tensile test)]×100Length before tensile test is a length of the laminated cured product obtained by laminating the cured film on the base to have an average thickness of 30 μm, and length after tensile test is a length of the laminated cured product after elongated with a tensile tester at a tensile speed of 20 mm/minute at 180 degrees C.