Polyol-Based Electron Beam Curable Compositions for Thick Ink Films
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Solution Overview
Problem
Current UV-curable inkjet solutions face challenges in achieving satisfactory cure through thick ink sections due to UV attenuation, leading to residual uncured monomers and potential contamination in packaging applications, especially in food and pharmaceutical packaging.
Innovation Solution
Incorporating alcohols, particularly polyols like diethylene glycol, triethylene glycol, and trimethylolpropane, which are essentially free of ethylenically unsaturated groups, to promote Electron Beam (EB) curing of compositions comprising ethylenically unsaturated monomers and oligomers, reducing the amount of uncured monomers and minimizing migration risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If UV-curable compositions are used for thick ink sections, then UV light penetration is required, but UV attenuation by pigments and photoinitiators prevents satisfactory cure at base levels
Solution Approach 1:
The patent replaces UV light-based curing (optical system) with electron beam curing (particle radiation system). Electron beams have much higher penetrating power through thick ink films containing pigments and photoinitiators, enabling complete cure at base levels where UV light is attenuated and cannot effectively polymerize monomers.
Solution Approach 2:
The patent changes the fundamental curing parameter from UV wavelength (100-400 nm) to electron beam energy (typically 50-200 keV). This parameter change allows the curing radiation to penetrate through thick ink sections (exceeding 20 μm) that completely block UV transmission, achieving uniform cure throughout the entire ink film thickness.
2Reliability
If conventional UV-curable inks are used, then photoinitiators are required for curing, but high concentrations of photoinitiators increase ink viscosity and cause migration issues
Solution Approach 1:
The patent eliminates the need for photoinitiators by replacing UV photochemical curing with electron beam-induced free radical curing. Electron beams directly ionize and excite monomer molecules, generating radicals without requiring photoinitiator mediators, thereby simplifying the ink formulation and eliminating migration issues associated with high photoinitiator concentrations.
3Object-affected harmful factors
If UV-curable inks are used for food packaging, then complete cure is required to prevent contamination, but UV attenuation leaves residual uncured monomers that can migrate
Solution Approach 1:
The patent replaces UV curing with electron beam curing to achieve complete polymerization of monomers in thick ink films. The high penetrating power and direct energy transfer of electron beams ensure that even monomers at the base level of thick ink sections (exceeding 20 μm) are fully cured, eliminating residual uncured monomers that could migrate and contaminate food products.
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 use of polyols significantly reduces the amount of uncured monomers in EB-cured ink films, enabling faster press speeds and minimizing contamination risks in packaging applications, while ensuring compliance with migration limits, particularly in food packaging.
Implementation Method 1
Electron Beam (EB) curable compositions comprising alcohol containing substances
Implementation Method 2
compositions comprising ethylenically unsaturated monomers and oligomers
Implementation Method 3
the inclusion of alcohols, and especially polyols... can promote the EB-curing of compositions comprising ethylenically unsaturated monomers and oligomers
Data Source
AI summary
Electron beam curable compositions including polyols, and any blend of ethylenically unsaturated monomers and oligomers. The polyols of the invention are preferably essentially free of any ethylenically unsaturated groups, have greater than one hydroxy group and preferably have boiling points in excess of 170° C.