Printed Polymer Substrate Composition for Inkjet Dot Gain Control
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Solution Overview
Problem
The interaction between the liquid resin layer and ink in inkjet printing processes affects dot gain, leading to issues with image sharpness and optical density, as too much dot gain results in a darker image than intended, while too little dot gain decreases optical density.
Innovation Solution
A printed substrate with a liquid polymer layer containing polyvinyl chloride, a plasticizer, a colorant, and calcium carbonate, where the weight ratio of calcium carbonate to polymer is between 0.1 to 3.5, and the layer is cured after inkjet printing to control dot gain and enhance optical density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a liquid resin layer is applied to the substrate for inkjet printing, then the printing process can be performed, but the dot gain varies and affects image sharpness and optical density
Solution Approach 1:
The patent changes the chemical composition parameters of the liquid resin layer by incorporating specific additives (calcium carbonate at 0.1-3.5 wt%, zinc oxide at 0.1-2.0 wt%, and titanium dioxide at 0.1-2.0 wt%) to control the interaction with ink and stabilize dot gain during the printing process
Solution Approach 2:
The patent creates a composite liquid resin layer by combining polyvinyl chloride with multiple functional additives (calcium carbonate, zinc oxide, titanium dioxide, and plasticizers) to achieve both printing performance and final product quality requirements
2Illumination intensity
If more ink is applied to achieve desired optical density, then the image becomes darker, but the dot gain increases and reduces image sharpness
Solution Approach 1:
The patent introduces calcium carbonate, zinc oxide, and titanium dioxide as intermediary substances in the liquid resin layer that mediate the interaction between ink and substrate, controlling ink spread and absorption to maintain optimal dot gain levels
3Manufacturing precision
If the liquid resin layer composition is modified to control dot gain, then image sharpness improves, but the composition complexity increases
Solution Approach 1:
The patent optimizes the concentration parameters of multiple additives within specific ranges (calcium carbonate 0.1-3.5 wt%, zinc oxide 0.1-2.0 wt%, titanium dioxide 0.1-2.0 wt%) to achieve dot gain control while managing composition complexity
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 controlled dot gain achieves sharper printed images with reduced ink usage, ensuring effective optical density and image quality.
Implementation Method 1
curing the liquid printed polymer layer to change the printed polymer layer from liquid to solid
Data Source
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AI summary
A printed substrate, wherein a printed polymer layer is present on a surface of the substrate, is disclosed. The printed polymer layer comprises a polymer chosen from one or more of polyvinyl chloride, a copolymer of vinyl chloride and vinyl acetate, and a terpolymer of vinyl chloride, vinyl acetate and ethylene; a plasticizer; a colorant; and calcium carbonate.