Method for producing recorded matter having three-dimensional image, device for producing recorded matter having three-dimensional image, and foam-promoting liquid
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Solution Overview
Problem
Existing methods for forming three-dimensional images face challenges such as difficulty in foaming portions with low light absorption properties, inconsistent foaming due to chemical agents, and peeling of the foaming layer from the substrate.
Innovation Solution
A method involving a foam-promoting liquid containing water and a component that lowers the foaming start temperature of thermally expandable particles, applied to a recording medium with a binder resin, forms a three-dimensional image by heating the foaming layer within specific temperature ranges, using thermoplastic resin-encapsulated particles to enhance adhesion and clarity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a chemical foaming agent is used to form three-dimensional images, then foaming can occur without light absorption requirements, but variations are generated in foamed portions making it difficult to express clear unevenness
Solution Approach 1:
The patent changes the foaming mechanism from chemical reaction-based to thermal expansion-based. By using thermally expandable particles that expand when heated to a specific temperature range, the invention achieves uniform and controllable foaming without the variations inherent in chemical foaming agents. This parameter change from chemical to thermal control resolves the contradiction between foaming capability and clear unevenness expression.
2Manufacturing precision
If ink containing color material with high light absorption properties is applied to portions desired to be thermally foamed, then selective foaming can be achieved, but it is difficult to foam portions to which ink with low light absorption properties is applied
Solution Approach 1:
The patent replaces the optical-based selective foaming system (using light-absorbing inks and light irradiation) with a thermal-based system. By applying a heat-sensitive liquid that lowers the foaming start temperature of particles, the invention enables selective foaming through thermal diffusion rather than light absorption, thereby expanding the range of foamable portions while maintaining manufacturing precision.
3Manufacturing precision
If foamable capsules are heated to form three-dimensional image, then three-dimensional image can be formed, but the three-dimensional image forming layer may peel off the support
Solution Approach 1:
The patent changes the heating approach by using a heat-sensitive liquid that diffuses thermal energy and lowers the foaming start temperature. This gradual thermal process reduces thermal stress and prevents peeling, while still achieving the desired three-dimensional image formation. The liquid acts as a thermal mediator that protects the adhesion between layers.
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
This approach allows for clear uneven structures to be expressed in three-dimensional images while preventing peeling from the substrate, improving the formation process and image quality.
Implementation Method 1
a foaming layer being provided on the substrate and containing a binder resin and a foaming particle which is foamed by heat
Implementation Method 2
a volatile material encapsulated in the shell layer
Implementation Method 3
foaming the foaming particle to form a three-dimensional image by heating the foaming layer
Data Source
AI summary
A recorded matter having a three-dimensional image is produced by a method comprising the steps of: applying, to a recording medium including a substrate and a foaming layer provided thereon, a foam-promoting liquid containing water and a foam-promoting component; and heating the foaming layer. The foaming layer contains a binder resin and a foaming particle which foams as heated, while the foam-promoting component lowers a foaming start temperature of the foaming particle. The foaming particle includes a shell layer containing a thermoplastic resin and a volatile material encapsulated in the shell layer. The binder resin contains a water-insoluble resin, while the foam-promoting component contains a compound having no hydroxyl group.