Multi-Stage Curing Ink for Vinyl Film Adhesion
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Solution Overview
Problem
Current radiation-curable inks for vinyl films are unsuitable for producing luxury vinyl tiles (LVTs) and melamine-based products due to low inner strength, impact resistance, and poor compatibility with carrier layers, requiring additional adhesive systems that increase costs and environmental concerns.
Innovation Solution
Development of multi-stage curing inks for inkjet printing that form an organic matrix via radical polymerization and an inorganic matrix via non-radical polymerization, using alkoxysilanes and structure-reinforcing polymers with high molecular mass to enhance adhesion and cohesion between vinyl or polyester films and melamine-based overlays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If radiation-curable inks are used for printing vinyl films, then the print is fixed immediately with maximum colour brilliance and sharpness, but the cured ink layers have low inner strength and poor adhesion to carrier layers
Solution Approach 1:
The patent uses composite materials by combining organic matrix formers (acrylates, methacrylates) with inorganic matrix formers (alkoxysilanes) to create a hybrid curing system. This composite approach allows the ink to achieve both immediate radiation curing for color sharpness and subsequent thermal curing for enhanced mechanical strength and adhesion, resolving the contradiction between quick fixation and structural integrity
Solution Approach 2:
The curing process is segmented into two distinct stages: first, radiation-induced radical polymerization provides immediate fixation and color brilliance; second, thermal treatment completes the reaction of alkoxysilane groups to achieve full mechanical strength and adhesion. This segmentation allows each curing mechanism to optimize its contribution without interfering with the other
2Strength
If additional adhesive systems are used to improve adhesion between films, then bonding strength increases, but production complexity and environmental concerns increase
Solution Approach 1:
The ink composition serves multiple functions simultaneously: it acts as the printing medium for color application, provides the adhesive bridge between the decorative film and carrier layer, and forms the intermediate layer for lamination. This multi-functionality eliminates the need for separate adhesive systems, reducing production complexity while maintaining strong bonding
Solution Approach 2:
The patent merges the functions of the printing ink and the adhesive system into a single integrated composition. The ink contains both the colorants and the adhesion-promoting components (organic and inorganic matrix formers), combining what were previously separate application steps into one unified process
3Strength
If solvent-based or aqueous inks are used for printing, then adhesion can be improved, but the applied colours can diffuse into one another, reducing colour brilliance and sharpness
Solution Approach 1:
The radiation-curable components are activated immediately upon application to the substrate, forming a preliminary fixed layer that prevents color diffusion. This preliminary action of rapid curing locks the colors in place before they can spread, while the subsequent thermal curing step then enhances adhesion without causing color migration
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 multi-stage curing inks improve the shear strength and adhesion of LVTs and melamine-based products, eliminating the need for additional adhesive systems and reducing environmental impact by providing excellent bonding and structural integrity.
Implementation Method 1
compounds for forming at least one organic matrix which is cured via radical polymerisation and which curing can be initiated by radiation
Implementation Method 2
compounds for forming at least one inorganic matrix which is cured via non-radical polymerisation and which curing can be initiated thermally
Data Source
AI summary
The invention relates to a multi-stage curing ink comprising compounds for forming at least one organic matrix, which is cured via radical polymerisation and which curing can be initiated by radiation, and comprising alkoxysilane in a quantity of 10 to 60 wt. %, preferably 20 to 50 wt. %, in relation to the total formulation, in order to form at least one inorganic matrix, which is cured via non-radical polymerisation and which curing can be initiated thermally, the ink also including a structure-reinforcing polymer having a number average molecular mass (Mn) of greater than 3000 g/mol, preferably greater than 10,000 g/mol, and particularly preferably greater than 30,000 g/mol, and the viscosity of the ink at 50° C. is in the region of 6 to 15 mPa·s, particularly preferably in the region of 9 to 11 mPa·s, measured with a Brookfield rheometer using a UL adapter with a rotational speed of 50 rotations per minute.