Ultra low thermo fusion PVC alternative plastisol coating and textile printing ink
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Solution Overview
Problem
Conventional PVC plastisol curing at high temperatures poses health hazards, requires high energy consumption, and is not suitable for heat-sensitive substrates, leading to issues like toxic gas emission, mechanical stress, and poor adhesion, while existing low-temperature alternatives have short shelf-life and poor durability.
Innovation Solution
A novel PVC-free plastisol composition using a combination of acrylate polymer and specific plasticizers, such as 2,2,4-trimethyl-1,3 pentanediol diisobutyrate, dioctyl terephthalate, and benzyl butyl 1,2-cyclohexyldicarboxylate, which cures at lower temperatures, providing superior bonding, durability, and adhesion without the need for flash curing or additional bonding agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional PVC plastisol is cured at high temperatures (around 177°C), then the plastisol cures and forms a flexible permeant solid, but toxic hydrogen chloride gas is released and high energy consumption is required
Solution Approach 1:
The patent changes the chemical composition parameters of the plastisol by replacing PVC with alternative polymers (acrylic, polyester, polyurethane, vinyl acetate) and adjusting plasticizer ratios, enabling the material to cure at lower temperatures (90-150°C) while maintaining curing effectiveness and eliminating toxic HCl gas emission
Solution Approach 2:
The patent uses composite material formulations combining multiple polymer types (acrylic, polyester, polyurethane, vinyl acetate) with specific plasticizer blends to create a plastisol that achieves effective curing at reduced temperatures without releasing toxic gases, thus resolving both curing reliability and harmful emission issues
2Reliability
If conventional PVC plastisol is cured at high temperatures (around 177°C), then the plastisol cures and forms a flexible permeant solid, but high energy consumption is required
Solution Approach 1:
The patent modifies the chemical parameters of the plastisol formulation by using alternative polymers and plasticizers with lower curing temperature requirements, reducing the curing temperature from 177°C to 90-150°C and thereby significantly decreasing energy consumption while maintaining curing effectiveness
3Reliability
If conventional PVC plastisol is cured at high temperatures (around 177°C), then the plastisol cures properly, but heat-sensitive substrates (acrylic, polyester, spandex, nylon, polypropylene, artificial leather, rubber) cannot be used
Solution Approach 1:
The patent changes the curing temperature parameter from high (177°C) to low (90-150°C), making the plastisol compatible with heat-sensitive substrates such as acrylic, polyester, spandex, nylon, polypropylene, artificial leather, and rubber, thereby expanding substrate compatibility while maintaining curing effectiveness
Solution Approach 2:
The patent creates a universal plastisol formulation that can be applied to diverse substrates including both conventional and heat-sensitive materials by using temperature-independent curing chemistry, achieving broad adaptability across different substrate types
4Object-generated harmful factors
If existing low-temperature curing plastisol alternatives are used, then toxic gas emission is reduced, but shelf-life becomes short and durability is poor
Solution Approach 1:
The patent employs composite material formulations combining multiple stable polymers (acrylic, polyester, polyurethane, vinyl acetate) with carefully selected plasticizers to create a plastisol that achieves low-temperature curing without compromising shelf-life or durability, resolving the trade-off between reduced toxicity and maintained reliability
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 reduces energy consumption, eliminates toxic gas emissions, and allows for use on heat-sensitive materials with improved durability and adhesion, extending shelf-life and reducing the need for cooling measures in multicolor applications.
Implementation Method 1
a PVC alternative plastisol that cures at temperatures lower than conventional compositions
Implementation Method 2
a liquid plasticizer with various other agents to achieve desired properties
Data Source
AI summary
The present invention relates to a novel PVC-free plastisol composition that cures at a temperature much lower than conventional plastisols. The plastisol composition includes an acrylate polymer; and a plasticizer mixture comprising at least three plasticizers selected from the group consisting of 2,2,4-trimethyl-1,3 pentanediol diisobutyrate, dioctyl terephthalate, dibutyl terephthalate, and benzyl butyl 1,2-cyclohexyldicarboxylate. Also disclosed is a method of applying the composition.