Laminated Film In-Line Curing for Ink Adhesion and Productivity
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Solution Overview
Problem
Existing methods for producing laminated films with a plastic film substrate face issues of insufficient ink curability and adhesion between the ink and the second substrate, requiring long aging processes that reduce productivity.
Innovation Solution
A method involving the application of an active energy ray-curable printing ink followed by an adhesive, with both steps performed in-line, and subsequent curing with an active energy ray to enhance ink curability and adhesion, using either an active energy ray-curable adhesive or a non-solvent isocyanate adhesive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If an active energy ray-curable printing ink is used for printing on plastic film, then the ink can be cured at room temperature in a short time, but the curability of the ink and adhesion between the ink and the plastic film become insufficient
Solution Approach 1:
The patent introduces an adhesive layer as an intermediary between the printed ink layer and the second substrate. This adhesive layer mediates the bonding process, ensuring strong adhesion between the ink-containing first substrate and the second substrate without compromising the rapid curing characteristics of the active energy ray-curable ink. The adhesive composition is specifically designed to be compatible with both the cured ink and the second substrate materials.
2Reliability
If an isocyanate-curing adhesive is used for lamination, then adhesion between the ink and the second substrate can be achieved, but a long aging process such as processing at 40° C. for 3 days is required
Solution Approach 1:
The patent modifies the adhesive composition parameters by incorporating specific functional groups and adjusting the molecular structure of the adhesive components. This enables the adhesive to achieve full curing strength without requiring extended aging processes. The adhesive formulation is optimized to provide rapid initial bonding followed by complete curing, eliminating the need for prolonged thermal aging while maintaining strong adhesion between layers.
3Productivity
If active energy ray irradiation is performed to cure the printing ink, then the ink can be cured instantly, but the surface of the ink is exposed to oxygen which reduces curability and adhesion
Solution Approach 1:
The patent applies the adhesive composition onto the printed substrate before completing the ink curing process. This preliminary application of the adhesive creates a protective environment that limits oxygen exposure to the ink surface during the critical curing phase. The adhesive layer acts as a barrier that prevents oxygen from interfering with the photopolymerization reaction, thereby maintaining both rapid curing and strong adhesion properties.
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 produces laminated films with improved ink curability and adhesion between the ink and the second substrate, enhancing productivity by reducing lead time and processing loss.
Implementation Method 1
a curing step of irradiating the active energy ray-curable printing ink with an active energy ray to cure the active energy ray-curable printing ink
Data Source
AI summary
An object of the present invention is to provide a method for producing a laminated film, the method capable of producing a laminated film excellent in curability of an ink and adhesion between the ink and a second substrate with high productivity.The present invention is a method for producing a laminated film, the method including: a printing step of applying an active energy ray-curable printing ink to a first substrate film formed of at least a plastic film; an adhesive application step of applying an adhesive; and a lamination step of laminating a second substrate, the steps being performed in this order in-line, the method further including a curing step of irradiating the active energy ray-curable printing ink with an active energy ray to cure the active energy ray-curable printing ink after at least the adhesive application step.