Multilayered 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 a multilayered structure formed by applying a release coating, printing ink layers, and curable compositions containing polymer powders, plasticizers, and monomers/oligomers, followed by heating and crosslinking to enhance interlayer cohesion and adhesion, using techniques like UV or thermal initiators for crosslinking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional printing methods are used to produce indicia and stencils, then production is simple and fast, but adhesion and interlayer cohesion are inferior
Solution Approach 1:
The patent uses a multilayered structure combining release coating, printing ink layers, and curable composition layers with polymer powders. This composite material approach provides superior adhesion and interlayer cohesion compared to conventional single-layer printing methods, while maintaining production efficiency through integrated curing processes.
Solution Approach 2:
The patent applies controlled heating (70-120°C for gelling, 130-160°C for diffusion, 165-190°C for crosslinking) and UV irradiation to transform the physical and chemical properties of the coating layers. These parameter changes enable progressive curing at different stages, improving adhesion without requiring excessively complex equipment.
2Strength
If multiple layers are applied to improve durability, then strength and endurance are enhanced, but interlayer cohesion problems occur
Solution Approach 1:
The patent applies a release coating to the substrate before applying subsequent layers, preventing premature adhesion and allowing controlled layer-by-layer construction. This preliminary action ensures that each layer can be applied and positioned correctly before bonding to the next layer, maintaining interlayer cohesion throughout the multilayer structure.
Solution Approach 2:
The curable composition undergoes phase transitions during processing: first gelling at 70-120°C to form a stable intermediate structure, then diffusing at 130-160°C to achieve interlayer penetration, and finally crosslinking at 165-190°C or via UV irradiation to lock in strong interlayer cohesion. These controlled phase transitions prevent layer separation while building durability.
3Ease of manufacture
If volatile compounds are used in the coating composition, then application and curing are easier, but shrinkage and residue are produced
Solution Approach 1:
The patent uses controlled temperature progression (70-120°C gelling, 130-160°C diffusion, 165-190°C crosslinking) to evaporate volatile compounds at optimized rates. This prevents sudden shrinkage from rapid evaporation while ensuring complete removal of volatiles to avoid residue. The gradual parameter change maintains application ease while eliminating harmful effects.
Solution Approach 2:
The patent replaces conventional thermal drying with UV irradiation for crosslinking in some embodiments. This substitution allows curing without excessive heat that would cause volatile compound migration and shrinkage, while still achieving easy application and rapid curing. The UV energy directly initiates polymerization without relying on volatile solvent evaporation.
4Strength
If high temperature curing is applied to improve crosslinking, then adhesion improves, but premature polymer curing occurs
Solution Approach 1:
The patent applies a release coating and optionally printing ink layers before applying the curable composition. These preliminary layers are heat-resistant and provide a stable base that can withstand the high-temperature crosslinking (165-190°C) without degrading or causing premature curing of the curable composition. This preliminary preparation allows controlled timing of the actual crosslinking process.
Solution Approach 2:
The curable composition undergoes a two-stage phase transition: first gelling at lower temperature (70-120°C) to form a stable, non-tacky intermediate structure that prevents premature final curing, then crosslinking at high temperature (165-190°C) or via UV irradiation to achieve final adhesion. This staged phase transition controls the timing and extent of polymer curing, preventing premature setting while ensuring complete crosslinking for strong adhesion.
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 improved adhesion and dimensional stability without edge curling or residue, making the printed indicia/stencils more durable and environmentally friendly.
Implementation Method 1
heating the curable coating composition to a temperature of about 70 to about 120°C, to provide a gelled curable coating
Implementation Method 2
the multilayer-coated substrate formed is heated to a temperature of about 130 to about 160°C
Implementation Method 3
crosslinking the heated multilayer-coated substrate, by irradiation and/or subjection to heat at a temperature of about 165 to about 190°C
Data Source
Figure 1~5
AI summary
The present invention relates to a method of producing a multilayered printed indicia or stencil, comprising the steps of: optionally providing a release coating on a substrate; optionally providing a printing ink layer onto said release coating; providing a coating of a 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; heating the curable coating composition to a temperature of 70-120°C, to provide a gelled curable coating; optionally providing a printing ink layer onto said gelled polymer coating, providing a coating of another 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; and heating the other curable composition coating to a temperature of 70-120°C, to provide second gelled curable coating; before crosslinking is performed, the multilayer-coated substrate formed is heated to a temperature of 130-160°C; and crosslinking the heated multilayer-coated substrate, by irradiation and/or subjection to heat at a temperature of 165-190°C; wherein optionally a pressure sensitive adhesive composition coating is provided to the release coating on the substrate before further coatings are applied, or is provided to the gelled polymer coating which was last formed, if more than one is present.