LED-Curable Offset Ink with Aluminum Additives for Reduced Misting
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Solution Overview
Problem
UV-LED inks exhibit poor lithographic press performance and high brittleness due to high polarity and oxygen inhibition, leading to misting issues during printing, which are not effectively addressed by existing solutions.
Innovation Solution
A composition of LED-curable inks containing 25-85% acrylates, 0-20% photoinitiators, 5-60% rosin-modified polyester resins, 0.2-5% aluminum additives, and 0.1-5% polymerization stabilizers, which enhances lithographic properties and reduces misting while maintaining LED drying efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If UV-LED inks are used to achieve fast drying and sustainability, then energy efficiency and productivity are improved, but lithographic press performance deteriorates due to high polarity and oxygen inhibition
Solution Approach 1:
The patent introduces an intermediary substance (rosin resin or carboxylic acid) that mediates between the polar acrylate monomers and the lithographic printing process. This intermediary reduces the overall polarity of the ink composition, allowing UV-LED inks to maintain fast drying properties while improving compatibility with lithographic presses and fountain solutions.
Solution Approach 2:
The patent changes the chemical parameters of the ink composition by incorporating specific ratios of acrylate monomers (20-80 wt%), rosin resin (5-40 wt%), and carboxylic acid (1-10 wt%). This parameter adjustment modifies the polarity and surface properties of the ink, enabling it to perform well in both LED curing and lithographic printing processes.
2Reliability
If multifunctional monomers are used to counteract oxygen inhibition, then surface cure is improved, but brittleness increases and adhesion deteriorates
Solution Approach 1:
The patent optimizes the concentration of multifunctional monomers (acrylates with 2-6 functional groups) within specific ranges (20-80 wt%) and combines them with rosin resin and carboxylic acid additives. This controlled parameter adjustment ensures sufficient crosslinking density for good surface cure while preventing excessive brittleness that would harm adhesion.
Solution Approach 2:
The patent creates a composite ink system combining multiple components: acrylate monomers, rosin resin, carboxylic acid, and photoinitiators. This composite approach allows the different materials to work synergistically - the acrylates provide crosslinking for surface cure, while the rosin and carboxylic acid components maintain flexibility and adhesion properties.
3Reliability
If rosin resin is added to improve lithographic properties, then press performance is improved, but solubility issues arise at high temperatures
Solution Approach 1:
The patent uses carboxylic acid as an intermediary substance that facilitates the solubility of rosin resin in the acrylate-based ink composition. The carboxylic acid acts as a bridge, improving the compatibility between rosin and acrylates, thereby enabling rosin to be effectively incorporated without causing solubility problems even at elevated temperatures during ink preparation.
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 composition achieves excellent press performance with reduced misting and maintains fast drying properties, improving adhesion and cohesion in LED-curable inks.
Implementation Method 1
LED curable printing ink or varnish compositions suitable for offset printing... containing an aluminum additive... can be cured with LED light
Implementation Method 2
0.2-5% of one or more aluminum additives... aluminum additives... improves adhesion and cohesion in LED-curable inks
Implementation Method 3
5-60% of one or more rosin-modified polyester resins... good solubility in highly functional acrylates
Data Source
AI summary
An LED curable lithographic ink comprising: 25-85% of one or more acrylates, wherein at least one acrylate is a pentaacrylate or hexaacrylate; 0-20% of one or more photoinitiators; 5-60% of one or more rosin-modified polyester resins, wherein the rosin-modified polyester resin has a molecular weight of 5,000 to 35,000 Daltons; 0.2-5% of one or more aluminum additives; 0.1-5% of one or more polymerization stabilizers; and 0-50% colorant.