Printed Material Bonding Using Phase-Transition Particles

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Solution Overview

Problem

Existing methods for forming printed materials with high peel strength are limited by the range of usable recording media and require high pressures, which can lead to issues like wrinkling and breaking, and do not effectively utilize the thermal properties of particles for bonding.

Innovation Solution

A method involving the application of particles containing styrene resin and (meth)acrylic acid ester resin, with a mass ratio of (meth)acrylic acid ester monomer units at 90% or more, which undergo pressure-induced phase transition, are heated and then pressed between layers of a recording medium to form a multilayer body, allowing for bonding at lower pressures and wider selection of recording media.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If high pressure is applied for bonding, then bond strength is improved, but recording medium degradation (wrinkling and breaking) occurs

Engineering Contradiction:

Improvebond strengthVSAvoidrecording medium degradation

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The invention changes the temperature parameter by heating the particles to their glass transition temperature or higher before bonding. This thermal parameter change softens the particles, enabling them to deform and bond effectively at lower pressures, thus preventing recording medium degradation while maintaining bond strength.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention utilizes the phase transition of particles from a rigid glassy state to a softened rubbery state by heating them to their glass transition temperature. This phase transition enables the particles to become pliable and form strong bonds under reduced pressure, avoiding damage to the recording medium.

Inventive Principle:

Principle #36Phase transitions

2Adaptability or versatility

If conventional particles are used, then bonding is achieved, but the range of usable recording media is limited

Engineering Contradiction:

Improverange of usable recording mediaVSAvoidbonding effectiveness

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The invention modifies the glass transition temperature parameter of the particles to match or exceed the melting points of various recording media. This parameter adjustment allows the particles to remain solid during handling but soften effectively when heated, enabling reliable bonding across diverse recording media types without limiting adaptability.

Inventive Principle:

Principle #35Parameter changes

3Strength

If particles are not heated before bonding, then process simplicity is maintained, but peel strength is insufficient

Engineering Contradiction:

Improvepeel strengthVSAvoidprocess complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The invention applies preliminary heating action to the particles before the bonding step. By pre-heating the particles to their glass transition temperature, they are prepared in advance to achieve optimal bonding characteristics, resulting in high peel strength while the heating process can be integrated into existing bonding equipment.

Inventive Principle:

Principle #10Preliminary action

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

This method enables the formation of printed materials with high peel strength while reducing the pressure required for bonding, thus minimizing degradation and expanding the range of usable recording media, through the use of particles that fluidize and re-solidify under pressure, enhancing bondability.

Implementation Method 1

The particles have two glass transition temperatures, and a difference between the lowest glass transition temperature and the highest glass transition temperature is 30° C. or more. The particles are heated to a temperature equal to or higher than the glass transition temperature

Methodology Applied

Scientific EffectGlass transition: Phase Change

Implementation Method 2

pressurizing, in a thickness direction, a multilayer body obtained by folding the recording medium so that the heated particles are sandwiched between flaps of the recording medium

Methodology Applied

Scientific EffectPressure-induced phase transition: Phase Change

Data Source

PatentUS11235593B2Method for forming printed material and system for forming printed material

Publication Date: 2022.02.01 FUJIFILM BUSINESS INNOVATION CORP

AI summary

A method for forming a printed material includes forming an image on a recording medium; applying particles to a surface of the recording medium, the surface having the image formed thereon; heating the particles applied to the recording medium; and pressurizing, in a thickness direction, a multilayer body obtained by folding the recording medium so that the heated particles are sandwiched between flaps of the recording medium or a multilayer body obtained by placing another medium on top of the recording medium with the heated particles therebetween. The particles contain a styrene resin and a (meth)acrylic acid ester resin. The (meth)acrylic acid ester resin contains two (meth)acrylic acid ester monomer units, and a mass ratio of the (meth)acrylic acid ester monomer units relative to a total of polymerization components is 90 mass % or more.