Multilayer Printed Indicia Adhesion via Curable Polymer Coatings
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Solution Overview
Problem
Existing printed indicia and stencils face issues such as inferior adhesion, interlayer cohesion, and migration of volatile compounds, leading to problems like shrinkage, curling edges, and residue left on surfaces upon removal.
Innovation Solution
A method involving the application of curable compositions comprising polymer powders, plasticizers, and monomers/oligomers, followed by heating and crosslinking, to create a multilayered structure with improved interlayer cohesion and adhesion, using techniques like UV or EB irradiation to form a solid coating with enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional printing inks and adhesives are used, then the production process is simple, but adhesion and interlayer cohesion are inferior
Solution Approach 1:
The patent uses composite materials consisting of polymer powders, plasticizers, monomers, and oligomers combined in specific ratios to create a curable composition that forms strong interlayer bonds. This composite approach enables superior adhesion and interlayer cohesion while maintaining processability through controlled curing mechanisms.
Solution Approach 2:
The patent employs parameter changes by controlling temperature, time, and chemical composition during the curing process. By adjusting these parameters, the material transitions from a soft, adhesive state to a cured, strong bond state, achieving high strength without excessive process complexity.
2Ease of manufacture
If volatile compounds are present in the composition, then the material is easier to process, but migration of volatiles causes shrinkage, curling edges, and residue
Solution Approach 1:
The patent uses parameter changes by carefully controlling temperature profiles during processing and curing. By maintaining temperatures within specific ranges and controlling humidity levels, the material processes easily while minimizing volatile migration that causes defects like shrinkage and curling.
Solution Approach 2:
The patent converts the potential harm of volatile compounds into a benefit by using controlled evaporation during the curing process. The volatiles are managed through controlled release during curing, transforming what would be a defect into part of the desired curing mechanism, reducing residue and improving final product quality.
3Adaptability or versatility
If multiple layers are applied to improve functionality, then the product performance increases, but interlayer cohesion and adhesion deteriorate
Solution Approach 1:
The patent applies homogeneity by ensuring uniform distribution of polymer powders, plasticizers, monomers, and oligomers across multiple layers. This homogeneous composition throughout all layers ensures consistent adhesion and interlayer cohesion, allowing multiple layers to be applied without compromising bond strength.
Solution Approach 2:
The patent uses composite materials with specific ratios of polymer powders, plasticizers, monomers, and oligomers that work synergistically across multiple layers. This composite formulation maintains strong interlayer bonds while enabling enhanced product functionality through multi-layer construction.
4Duration of action of stationary object
If conventional materials are used, then the production cost is lower, but long-term strength and endurance are insufficient
Solution Approach 1:
The patent employs composite materials with optimized ratios of polymer powders, plasticizers, monomers, and oligomers that provide superior long-term strength and endurance. While the material composition is enhanced, the manufacturing process remains cost-effective through controlled curing and efficient resource utilization.
Solution Approach 2:
The patent applies preliminary action by pre-mixing and pre-preparing the curable composition with optimal ratios of components before application. This preliminary preparation ensures long-term durability and strength while streamlining the manufacturing process and reducing overall production costs through efficient material utilization.
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 method provides long-term strength and endurance, prevents volatile losses, and allows for recycling, resulting in a durable and environmentally friendly multilayered printed indicia or stencil with improved adhesion and dimensional stability.
Implementation Method 1
heating the curable coating composition to a temperature of about 70-about 120° C., to provide a gelled curable coating
Implementation Method 2
the plasticizer/monomer/oligomer mixture to be absorbed in the polymer powder to avoid premature polymer curing
Implementation Method 3
crosslinking the heated multilayer-coated substrate, by irradiation and/or subjection to heat at a temperature of about 165-about 190° C.
Data Source
AI summary
In embodiments, the present invention relates to a method of producing a multilayered printed item, comprising: (a) providing a coating of curable composition comprising a polymer powder, at least one plasticizer, and at least one monomer and/or oligomer, onto the substrate or a thereon previously applied layer or coating; (b) heating the curable coating composition to a temperature of about 70-120° C., to provide a gelled curable coating; (c) providing a coating of curable composition comprising a polymer powder, at least one plasticizer, and at least one monomer and/or oligomer, onto the previously applied layer or coating; (d) heating the other curable as above, to provide second gelled curable coating; (e) before crosslinking is performed, the multilayer-coated substrate formed is heated to a temperature of about 130-160° C.; and (f) crosslinking the heated multilayer-coated substrate, by irradiation and/or subjection to heat at a temperature of about 165-190° C.