Non-Sparking Metallic Ink Formulation for High-Speed Presses
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Solution Overview
Problem
Metallic pigment-containing inks, particularly those with nitrocellulose resin, are prone to sparking and combustion during high-speed printing, posing safety hazards due to friction and potential combustion.
Innovation Solution
Formulating metallic pigment-containing inks with 9.0wt% or less nitrocellulose resin, or essentially free of nitrocellulose resin, to reduce the likelihood of sparking and combustion, and combining these inks with non-metallic inks that are also nitrocellulose resin-free or have minimal nitrocellulose resin, to ensure safety in high-speed printing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If metallic pigment-containing inks with nitrocellulose resin are used to achieve attractive metallic appearance, then the aesthetic quality is improved, but the safety hazard due to sparking and combustion increases
Solution Approach 1:
The patent removes nitrocellulose resin from the ink formulation to eliminate the sparking hazard while preserving the metallic appearance through alternative binder resins. This extraction of the harmful component directly resolves the contradiction between aesthetic quality and safety.
Solution Approach 2:
The patent changes the chemical composition parameters of the ink by substituting nitrocellulose resin with alternative binders and adjusting the metallic pigment concentration. This parameter change eliminates the combustion risk while maintaining the desired metallic visual effect.
2Productivity
If high-speed printing operations are conducted to increase productivity, then the output is improved, but the friction-induced sparking risk increases
Solution Approach 1:
By removing nitrocellulose resin from the ink formulation, the patent eliminates the fuel source that would otherwise combust under friction conditions during high-speed printing. This allows safe operation at high printing speeds without the sparking hazard.
Solution Approach 2:
The patent transforms the situation by using alternative resin formulations that, while potentially generating friction, do not create combustible conditions. The friction that would normally be harmful now becomes an acceptable operational parameter during high-speed printing.
3Quantity of substance
If water is added to dilute the ink formulation to reduce sparking, then the concentration of combustible materials is reduced, but hydrogen generation increases the explosion risk
Solution Approach 1:
The patent removes nitrocellulose resin from the formulation, eliminating the need for water dilution and the associated hydrogen generation risk. This extraction approach solves both the sparking problem and the potential explosion hazard from hydrogen.
Solution Approach 2:
The patent introduces alternative binder resins as intermediaries that replace the need for water dilution. These alternative resins provide the necessary ink properties without creating combustible conditions or hydrogen generation when water is present.
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 solution significantly reduces the risk of sparking and combustion, allowing safe operation on high-speed printing presses for extended periods without incidents, while maintaining the desired aesthetic and printing qualities.
Implementation Method 1
Hydrogen may be generated when, for example, an ink containing aluminum comes in contact with water. Hydrogen is potentially explosive and itself is a combustible material.
Implementation Method 2
At fast press speeds, the action of the doctor blade creates friction on the surface of the inked substrate, which can lead to sparking of the ink.
Data Source
AI summary
Described herein are metallic pigment-containing inks having a magnitude of exotherm < 1200 J/g, or no observable exotherm at all. Also described are metallic pigment-containing inks that include 9.0wt% or less nitrocellulose resin, or which are essentially free of nitrocellulose resin. Further described are articles printed with the described metallic pigment-containing inks, kits including such inks (and other inks), and methods of printing with such inks. The metallic pigment-containing ink described herein reduce, if not eliminate, the tendency of inks containing metallic pigments to spark and combust.