Offset Printing Recording Material Coating Mass Optimization
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Solution Overview
Problem
Existing recording materials for offset printing, especially at higher speeds, require costly protective layers for chemical resistance and scratch protection, which increases production costs and may not be necessary for all applications, while also needing to maintain layer sealing and resistance to picking forces.
Innovation Solution
A recording material with a substrate having a coating layer covering the entire surface, composed mainly of binders like ethylene-vinyl alcohol copolymer, polyvinyl alcohol, and crosslinking agents, applied in a specific mass range to enhance pick and scratch resistance without the need for a protective layer, using a method that incorporates a coating composition and crosslinking process to form a durable yet cost-effective solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective layer is applied to ensure chemical resistance and layer sealing, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent removes the separate protective layer from the structure, extracting only the essential function of layer sealing and chemical resistance. The recording layer itself is formulated to provide adequate protection without requiring an additional protective coating, thereby reducing manufacturing complexity and cost while maintaining reliability.
Solution Approach 2:
The recording layer is designed to serve multiple functions simultaneously: it provides the primary recording function, ensures layer sealing to prevent particle detachment, and offers chemical resistance. This multi-functionality eliminates the need for a separate protective layer, reducing manufacturing cost while maintaining reliability.
2Reliability
If a protective layer is applied to ensure layer sealing and resistance to picking forces, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent extracts the layer sealing function from a separate protective layer and integrates it into the recording layer formulation. The recording layer is designed with sufficient internal cohesion and adhesion to withstand picking forces during high-speed offset printing, eliminating the need for an additional protective layer and reducing manufacturing cost.
Solution Approach 2:
The recording layer uses a composite formulation combining binder resins, pigments, and optional additives that work together to provide both recording functionality and mechanical strength. This composite structure ensures adequate layer sealing and resistance to picking forces without requiring a separate protective layer, thereby reducing manufacturing complexity and cost.
3Reliability
If the coating layer mass per unit area is increased to improve scratch resistance, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent optimizes the mass per unit area of the coating layer to a specific range (0.05-0.8 g/m²) that provides adequate scratch resistance and layer sealing without excessive material application. This parameter optimization ensures reliable performance while controlling manufacturing costs by avoiding over-application of coating materials.
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 proposed recording material achieves improved scratch resistance and pick resistance at a lower cost, ensuring effective layer sealing and printability without the need for a protective layer, while maintaining price competitiveness and superior product features.
Implementation Method 1
The coating composition for forming a coating layer covering the entire surface of the recording layer and likewise the coating layer itself mainly comprises a binder
Implementation Method 2
the binders listed above as preferred being incorporated in the coating layer alone in a first particularly preferred embodiment, in a mixture with one another in a second particularly preferred embodiment or in a mixture with other binders in a third embodiment
Data Source
AI summary
A recording material for offset printing is proposed, having a substrate in web form, featuring a facing side and a reverse opposite the facing side; having at least one recording layer on at least one side of the substrate; having at least one coating layer that fully masks the recording layer; the new recording material is characterized in that the at least one coating layer that fully masks the recording layer has a mass per unit area of between 0.05 and 0.8 g/m2. In fact the mass per unit area is preferably within a range of 0.15 and 0.35 g/m2. Furthermore, a method is proposed for producing a recording material of this kind for offset printing.