Radiation-Curable Inorganic Nanoparticle Layers for Low-Gloss Laminates
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Solution Overview
Problem
Existing methods for achieving a low gloss appearance in films are costly and inefficient due to the need for mechanical means like embossing and limitations in inkjet printing with resin beads, which can cause sedimentation and viscosity issues.
Innovation Solution
A laminate with a surface layer containing a radiation-curable ink composed of inorganic nanoparticles and a polyether-modified polymer, allowing for uniform dispersion and transfer of nanoparticles to the surface upon irradiation, forming fine protrusions and recesses for a low gloss appearance without mechanical embossing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If mechanical embossment is used to achieve low gloss appearance, then the surface glossiness is reduced, but the device complexity and production cost increase due to requiring embossing rolls and maintenance
Solution Approach 1:
The patent replaces mechanical embossment systems with a chemical/coating-based solution. A surface layer containing inorganic nanoparticles is applied to the film, creating low gloss appearance through particle scattering rather than mechanical surface deformation. This eliminates the need for complex embossing rolls and their maintenance infrastructure.
Solution Approach 2:
The patent changes the surface properties by incorporating inorganic nanoparticles into a surface layer coating. The nanoparticle size, concentration, and distribution are controlled to achieve the desired light scattering effect and low gloss appearance, providing a parameter-based solution instead of mechanical processing.
2Illumination intensity
If resin beads are blended in ink for low gloss appearance, then the surface is roughened, but the resin beads sediment and the low gloss effect is not achieved
Solution Approach 1:
The patent uses inorganic nanoparticles instead of resin beads, fundamentally changing the particle size parameter. The nanoparticle dimensions create sufficient Brownian motion to counteract gravity-induced sedimentation, while also providing superior light scattering for low gloss effects. The nanoparticles remain stably suspended in the ink medium.
Solution Approach 2:
The patent creates a composite ink formulation combining inorganic nanoparticles with the binder resin and solvent system. This composite structure provides both the low gloss surface effect and the colloidal stability needed to prevent sedimentation during storage and application.
3Productivity
If conventional inkjet printing is used with resin beads, then printing is performed, but the viscosity is too high and resin beads cannot be used
Solution Approach 1:
The patent changes the particle size parameter from micrometer-scale resin beads to nanometer-scale inorganic particles. This size reduction dramatically decreases the viscosity contribution of the particles while maintaining their light-scattering functionality. The nanoparticle-containing ink achieves suitable viscosity for conventional inkjet printing processes.
4Illumination intensity
If inorganic nanoparticles are used in radiation-curable ink, then low gloss appearance is achieved with good dispersion, but the formulation complexity increases
Solution Approach 1:
The patent optimizes the nanoparticle size parameter and surface treatment to achieve natural compatibility with radiation-curable resin systems. The inorganic nanoparticles are surface-modified or selected to have appropriate surface chemistry that promotes uniform dispersion in the polymerizable medium without requiring complex dispersant packages or multi-step processing.
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 laminate achieves a low gloss appearance efficiently, reducing production costs and enhancing productivity by allowing various printing methods, including inkjet, while maintaining excellent elongation properties and weather resistance.
Implementation Method 1
the surface layer having a 60° surface glossiness of 50.0 GU or less
Implementation Method 2
a radiation-curable ink containing inorganic nanoparticles, a polyether-modified polymer, and at least one selected from the group consisting of a radiation-curable polymerizable oligomer and a radiation-curable polymerizable monomer
Data Source
AI summary
[Object] To provide a laminate having inorganic nanoparticle-containing surface layer that exhibits a low gloss appearance and inorganic nanoparticle-containing radiation-curable ink. [Resolution Means] A laminate of an embodiment of the present disclosure has a substrate and a surface layer containing a cured product of a radiation-curable ink, the radiation-curable ink containing inorganic nanoparticles, a polyether-modified polymer, and at least one selected from the group consisting of a radiation-curable polymerizable oligomer and a radiation-curable polymerizable monomer, and the surface layer having a 60° surface glossiness of 50.0 GU or less.