Recorded Matter Production with Segmented Clear Ink Layers
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Solution Overview
Problem
Ink jet recording methods face issues with image separation and marks remaining on the recording surface when clear ink layers are formed as solid image layers on roll-shaped recording media, leading to damage and poor image quality.
Innovation Solution
A method involving the use of radiation-curable ink jet compositions for forming a cured coating film with a first ink, followed by a second ink with controlled dot sizes and duty, and laminating the recording surface with the non-recording surface to reduce adhesion and improve peelability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a clear ink layer is formed as a solid image layer covering the entire region, then the recording surface provides good coverage and protection, but the recording surface sticks to the non-recording surface during roll storage, causing image separation and marks
Solution Approach 1:
The clear ink layer is segmented into multiple layers with different properties: a first clear ink layer formed as a solid image layer for coverage, and a second clear ink layer applied only to non-image areas with reduced adhesion. This segmentation allows the recording surface to have good coverage where needed while minimizing adhesion to the non-recording surface, preventing image separation and marks during roll storage.
Solution Approach 2:
Different regions of the recording surface are treated with different ink compositions and application methods. Image areas receive a solid clear ink layer for protection and gloss, while non-image areas receive a second clear ink layer with specifically controlled adhesion properties. This local differentiation ensures that adhesion occurs only where necessary for image protection, preventing sticking during storage without compromising image quality.
2Productivity
If the recording medium is wound into a roll shape for storage, then productivity and ease of handling are improved, but the recording surface adheres to the non-recording surface, damaging the recorded image
Solution Approach 1:
The clear ink application is segmented into two distinct steps: first, a solid clear ink layer is formed over the entire recording surface for protection; second, an additional clear ink layer is applied only to non-image areas with controlled adhesion properties. This segmentation enables the recording medium to be wound into rolls for efficient storage and handling while preventing adhesion between the recording and non-recording surfaces, thereby maintaining image integrity.
3Ease of manufacture
If a single clear ink layer is applied to the entire recording surface, then the process is simple and efficient, but adhesion to the non-recording surface causes marks and image separation
Solution Approach 1:
The clear ink application process is segmented into two steps with different objectives: the first step applies a solid clear ink layer across the entire recording surface for basic protection and gloss; the second step applies an additional clear ink layer specifically to non-image areas with controlled adhesion properties. This segmented approach maintains relative process simplicity while effectively preventing adhesion to the non-recording surface, avoiding marks and image separation.
Solution Approach 2:
The ink application process transitions from uniform coverage to localized treatment. The first clear ink layer provides universal coverage for protection, while the second clear ink layer is locally applied only to non-image areas with specifically tuned adhesion characteristics. This local quality differentiation resolves the contradiction by preventing surface adhesion in critical areas while maintaining process efficiency.
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 method enhances peelability between surfaces, reduces marks, and maintains image quality by minimizing adhesion to the non-recording surface, suitable for nonabsorptive recording media like films and plates.
Implementation Method 1
a first irradiation step of irradiating radiation to the first ink adhered to the recording medium to obtain a cured coating film of the first ink
Data Source
AI summary
A method for producing a recorded matter includes a first ejection step of ejecting a first ink, which is a radiation-curable ink jet composition, and adhering the first ink to a recording medium, a first irradiation step of irradiating radiation to the first ink adhered to the recording medium to obtain a cured coating film of the first ink, a second ejection step of ejecting a second ink, which is a radiation-curable ink jet composition, and adhering the second ink with a plurality of dot sizes to the cured coating film of the first ink so that the duty is less than 100%, a second irradiation step of irradiating radiation to the second ink adhered to the recording medium to cure the second ink, obtaining a recorded matter, and a lamination step of laminating, in the recorded matter, a recording surface to which the first ink and the second ink have been adhered, and a non-recording surface to which the first ink and the second ink have not been adhered, so that both surfaces face each other.