LED-Curable Offset Ink Composition for Low-Misting Press Performance
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Solution Overview
Problem
UV-LED inks exhibit poor lithographic press performance and misting issues due to high polarity and oxygen inhibition, leading to insufficient drying and ink contamination, while high solid content solutions exacerbate these problems.
Innovation Solution
A LED-curable ink composition comprising acrylates, rosin-modified polyester resins, aluminum additives, and polymerization stabilizers, which are soluble in highly functional acrylates and enhance cohesive forces, reducing misting and maintaining excellent press performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If UV-LED inks use high polarity acrylates for fast curing, then LED curing efficiency is improved, but lithographic press performance deteriorates and fountain interaction is adversely affected
Solution Approach 1:
The patent introduces a specific surfactant system comprising a fluorinated surfactant and a silicon-containing surfactant as intermediaries to mediate between the polar acrylate resin and the fountain solution. This surfactant combination reduces surface tension and improves wetting, enabling good fountain interaction despite the high polarity of the acrylate-based ink composition, thus resolving the contradiction between fast LED curing and press performance
Solution Approach 2:
The patent modifies the chemical composition parameters by using highly functional acrylates (pentaacrylate and hexaacrylate) with specific molecular structures and incorporating aluminum additives that alter the polar characteristics. These parameter changes enable the ink to maintain sufficient solubility and compatibility in the lithographic system while preserving fast LED curing properties
2Speed
If multifunctional monomers are used to overcome oxygen inhibition, then polymerization speed is improved, but brittleness increases and adhesion deteriorates
Solution Approach 1:
The patent creates a composite ink formulation combining highly functional acrylates (for fast polymerization) with aluminum additives and specific resins (for flexibility and adhesion). This composite approach allows the system to achieve rapid curing through the multifunctional monomers while the aluminum additives and resin components counteract brittleness and maintain good adhesion to substrates
Solution Approach 2:
The aluminum additives act as intermediaries between the rigid polymer network formed by multifunctional monomers and the substrate. These additives improve flexibility and adhesion, mediating the mechanical properties to prevent brittleness while maintaining fast polymerization speed enabled by the pentaacrylate and hexaacrylate components
3Object-generated harmful factors
If solid content is increased to reduce misting, then ink cohesion is improved, but press performance deteriorates due to particle agglomeration
Solution Approach 1:
The patent changes the chemical composition parameters by incorporating specific surfactants and aluminum additives that modify the surface properties and cohesive forces of the ink particles. These parameter changes allow the ink to maintain appropriate flow characteristics and prevent agglomeration on press, even with optimized solid content levels, thereby reducing misting without sacrificing press performance
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 ink composition achieves reduced misting and improved lithographic performance with efficient LED curing, maintaining high productivity and adhesion on various substrates.
Implementation Method 1
They can be cured by UV-LED light
Implementation Method 2
aluminum additives... which are soluble in highly functional acrylates and enhance cohesive forces
Data Source
Figure 1
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.