Laminated Film Substrate Crystal Size and Coating for Print Gloss
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Solution Overview
Problem
Biaxially oriented polyester films used in thermal transfer ribbons face challenges in achieving high glossiness and smooth processability, particularly due to issues with surface roughness, wrinkles, and heat shrinkage, which affect the quality of printed objects and the winding process.
Innovation Solution
A laminated film structure comprising a biaxially oriented polyester substrate layer with a coating layer on one or both sides, where the crystal size of the substrate's (100) plane is between 4.5 nm and 6.0 nm, and the coating layer has specific surface roughness and particle size characteristics, ensuring a heat shrinkage ratio of 0.5 to 2.5% and a coefficient of kinetic friction of 0.6 or less, enhancing the film's glossiness and processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the content of particles contained in the polyester film is decreased or the particle size is reduced to smoothen the surface, then the printing property is improved to a certain degree, but the shape appearance at winding deteriorates and the processability becomes complicated with wrinkles occurring
Solution Approach 1:
The invention uses a composite structure consisting of a polyester film substrate layer and a coating layer with different functional characteristics. The substrate layer provides mechanical strength and dimensional stability, while the coating layer provides the smooth printing surface. This composite structure allows the film to maintain both good printability and processability without wrinkles during winding and handling.
2Manufacturing precision
If the content of particles contained in the polyester film is decreased or the particle size is reduced to smoothen the surface, then the printing property is improved to a certain degree, but sufficient glossiness of printed objects cannot be obtained
Solution Approach 1:
The coating layer in the composite structure serves as a gloss-enhancing layer that compensates for the reduced particle content in the substrate. The specific particle size range (0.01-1.0 μm) and content (1-20 parts by weight per 100 parts of polyester resin) in the coating layer provide both smoothness for printing and sufficient glossiness for the printed objects.
Solution Approach 2:
The invention changes the particle size parameter to a specific range (0.01-1.0 μm) and controls the particle content (1-20 parts by weight per 100 parts of polyester resin) in the coating layer to achieve the optimal balance between smoothness and glossiness. This precise parameter control allows the coating layer to provide both printing smoothness and visual glossiness.
3Manufacturing precision
If a coating layer is added to improve surface properties, then the glossiness and printing property are improved, but the device complexity and manufacturing process become more complicated
Solution Approach 1:
The invention creates a composite material structure with a substrate layer and a coating layer, where the coating layer is applied to the substrate layer through lamination or coating processes. This composite structure improves glossiness and printing properties while maintaining relative simplicity in the overall manufacturing process by using standard coating or lamination techniques.
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 laminated film structure significantly improves the shape appearance at winding, processability, and achieves higher glossiness of printed objects by optimizing the substrate's thermal conductivity and surface properties, reducing wrinkles and ensuring uniform thermal transfer.
Implementation Method 1
the crystal size of a (100) plane of the layer A obtained by an X-ray diffraction measurement is 4.5 nm or more and less than 6.0 nm
Implementation Method 2
a higher heat shrinkage ratio of the laminated film between a heat shrinkage ratio in the longitudinal direction and a heat shrinkage ratio in the width direction at 150° C. for 30 minutes is 0.5 to 2.5%
Implementation Method 3
a surface opposite to the surface having the layer B has a center line average roughness (SRa) of 5 to 15 nm
Implementation Method 4
the coefficient of kinetic friction when, using two laminated films, the surface of the layer A and the surface of the layer B are laid on each other is 0.6 or less
Data Source
AI summary
A laminated film is provided which has excellent shape appearance at winding and also excellent processability and is capable of achieving higher glossiness of printed objects, the laminated film containing a substrate layer (layer A) composed of a biaxially oriented polyester film and a coating layer (layer B) on at least one side of the layer A, wherein the crystal size of the (100) plane of the layer A obtained by an X-ray diffraction measurement is 4.5 nm or more and less than 6.0 nm, a higher heat shrinkage ratio of the laminated film at 150° C. for 30 minutes between a heat shrinkage ratio in the longitudinal direction and a heat shrinkage ratio in the width direction at 150° C. for 30 minutes is 0.5 to 2.5%, the layer B is located on at least one outermost surface layer, and a surface opposite to the surface having the layer B has a center line average roughness (SRa) of 5 to 15 nm.