Laminated Resin Sheet Balancing Ink Adhesion and Laser Cutting
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Solution Overview
Problem
Methacrylic-based resins exhibit poor ink adhesion and laser cutting processability with UV curable inks, while styrene-based copolymers have favorable ink adhesion but poor laser cutting processability, leading to issues like unpleasant odors and smoke during laser cutting. Additionally, laminated sheets using recycled materials face transparency and compatibility challenges due to refractive index differences.
Innovation Solution
A laminated sheet with a base layer of methacrylic-based resin and a surface layer of styrene-based copolymer, where the surface layer's proportion is 1-20% of the total thickness, and the styrene-based monomer units are 0.1-25% by mass, ensuring compatibility and reducing evaporated gas issues during laser cutting, with a haze value of 4% or less for improved sustainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If styrene-based copolymers are used to improve ink adhesion, then ink adhesion is improved, but laser cutting processability deteriorates due to unpleasant odors and smoke
Solution Approach 1:
The resin sheet is divided into two distinct layers: a base layer made of methacrylic-based resin and a surface layer made of styrene-based copolymer. This segmentation allows each layer to perform its specialized function - the base layer provides good laser cutting processability while the surface layer provides excellent ink adhesion, thus resolving the contradiction between ink adhesion and laser cutting processability.
Solution Approach 2:
Different regions of the resin sheet are given different material properties. The surface layer (1-20% of total thickness) contains styrene-based copolymer for optimal ink adhesion, while the base layer (80-99% of total thickness) uses methacrylic-based resin for good laser cutting processability and reduced harmful emissions. This local differentiation of material quality resolves the contradiction by assigning each material to the region where it is most needed.
2Adaptability or versatility
If recycled laminated sheets are used as rework material, then sustainability is improved, but transparency deteriorates due to refractive index differences and cloudiness
Solution Approach 1:
The patent specifies precise parameter ranges for the laminated sheet structure to ensure optical compatibility. The surface layer thickness is controlled at 1-20% of total thickness, and the styrene-based copolymer content is limited to 0.1-25% by mass. These parameter controls ensure that when sheets are recycled and reprocessed, the refractive index differences remain within acceptable limits, preventing cloudiness and maintaining transparency while enabling sustainable reuse.
Solution Approach 2:
The patent creates a composite material system where methacrylic-based resin and styrene-based copolymer are combined in specific proportions and layer configurations. This composite structure is designed to have compatible optical properties that allow the material to be recycled and reprocessed multiple times without significant degradation in transparency, thus enabling sustainability while maintaining optical quality.
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 sheet achieves favorable ink adhesion and laser cutting processability, suppressing unpleasant odors and smoke, and maintains transparency using recycled materials, enhancing sustainability by utilizing a laminated structure with controlled styrene-based copolymer proportions.
Implementation Method 1
The resin sheet for inkjet printing after being subjected to inkjet printing can be cut using a laser
Implementation Method 2
As inks for inkjet printing, ultraviolet (UV) curable inks and the like are preferably used
Data Source
AI summary
The present disclosure provides a laminated sheet that has favorable ink adhesion and laser cutting processability, and is highly sustainable. The laminated sheet (1) of the present disclosure has a base layer (11) and a surface layer (21) laminated on at least one side of the base layer (11), the base layer (11) includes a methacrylic-based resin (M) including 80 to 100% by mass of methyl methacrylate units, the surface layer (21) includes a styrene-based copolymer(S), the proportion of the total thickness of the surface layer (21) to the total thickness of the laminated sheet (1) is 1 to 20%, and the haze value of a 3.0 mm-thick single-layer molded sheet of the pulverized material of the laminated sheet (1) is 4% or less.