PVC-Free Printable Medium with Flame-Retardant Barrier
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Solution Overview
Problem
Existing large format printing technologies face challenges in producing durable, high-quality prints on substrates like wall-coverings and banners, particularly in terms of ink absorption speed, bleed, and environmental sustainability, especially when using PVC-free materials that meet fire resistance and durability standards.
Innovation Solution
A printable medium with a non-woven base composite substrate, featuring an ink fixing layer, an image receiving layer with pigment fillers and polymeric binders, and a barrier layer containing a flame-retardant agent, designed for inkjet printing, which includes a salt-based ink fixing layer, a polymeric image receiving layer, and a flame-retardant barrier layer, ensuring fast ink absorption, low bleed, and high durability while being PVC-free and meeting fire resistance standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If PVC-free materials are used to meet environmental sustainability standards, then environmental safety is improved, but fire resistance and durability may be compromised
Solution Approach 1:
The patent employs a composite substrate structure combining wood fiber and synthetic polymer fibers (acrylic, polyester, or polyamide) in specific ratios. This composite approach allows the material to be PVC-free while achieving both fire resistance (through the synthetic components) and environmental sustainability (through the wood fiber content and absence of PVC). The composite structure enables simultaneous optimization of multiple properties that cannot be achieved with a single material type.
Solution Approach 2:
The patent specifies precise parameter ranges for the substrate composition (wood fiber 20-80 wt%, synthetic polymer 20-80 wt%) and coating weights (size press coating 0.5-5 gsm, bulk coating 1-10 gsm) to optimize the balance between fire resistance, durability, and environmental safety. By controlling these parameters, the material achieves Type-II commercial serviceability fire rating without using PVC.
2Productivity
If high-speed inkjet printing is implemented, then productivity is improved, but ink absorption speed and bleed control become more challenging
Solution Approach 1:
The patent applies a size press coating before the bulk coating to pre-condition the substrate surface. This preliminary sizing layer (0.5-5 gsm) prepares the substrate to control ink absorption at high speeds, preventing excessive bleed while maintaining fast absorption characteristics. The pre-coating ensures that when high-speed inkjet printing occurs, the ink is absorbed at the optimal rate without compromising image quality.
Solution Approach 2:
The patent creates different functional zones within the coating structure: the size press coating layer provides initial ink reception and absorption control, while the bulk coating layer (1-10 gsm) provides additional ink holding capacity and surface properties. This layered approach with different local properties enables the substrate to handle high-speed printing while maintaining precise ink absorption control and minimal bleed.
3Manufacturing precision
If multi-layer coating structure is added to improve print quality and durability, then image quality is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent divides the coating system into distinct functional layers: a size press coating layer (0.5-5 gsm) applied first, followed by a bulk coating layer (1-10 gsm) applied second. Each layer has specific compositional requirements and functions. This segmentation allows optimization of each layer's properties independently while maintaining overall simplicity. The size press layer handles initial ink reception, and the bulk layer provides additional image quality and durability, achieving high print quality without excessive 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 solution provides a durable, PVC-free printable medium that meets Type-II commercial serviceability standards, offers excellent water and scratch resistance, and supports high-speed printing with minimal ink bleed, while ensuring compliance with environmental and safety standards.
Implementation Method 1
an ink fixing layer, directly applied upon the supporting substrate, comprising a salt
Implementation Method 2
an image receiving layer, applied over the ink fixing layer, including pigment fillers and polymeric binders
Implementation Method 3
a barrier layer, containing a flame-retardant agent, applied on the backside of the composite supporting substrate
Data Source
AI summary
A printable medium with a non-woven base composite supporting substrate; at least two coating layers, on the image side of the composite supporting substrate, that include an ink fixing layer, directly applied upon the supporting substrate, comprising a salt; and an image receiving layer, applied over the ink fixing layer, including pigment fillers and polymeric binders; and a barrier layer, containing a flame-retardant agent, applied on the backside of the composite supporting substrate. Also disclosed are the method for producing printed images using said media and the resulting printed material.