Heat-Sensitive Recording Material With Sized Hollow Particles
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Solution Overview
Problem
Existing heat-sensitive recording materials suffer from insufficient heat insulation properties, leading to print energy diffusion and reduced recording density, as well as issues with particle diameter uniformity affecting image quality and surface strength.
Innovation Solution
A heat-sensitive recording material with an undercoat layer containing hollow particles and inorganic pigment, where the hollow particles have specific diameter and diameter distribution ranges, and a binding resin with low glass transition temperature, enhancing heat insulation and image quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If hollow particles with small particle diameters (1-10 μm) are incorporated into the undercoat layer to improve heat insulation, then the heat insulation properties are enhanced, but the recording density deteriorates due to print energy diffusion
Solution Approach 1:
The patent changes the particle diameter parameter of hollow particles from small (1-10 μm) to large (10-30 μm) to resolve the contradiction. This parameter change increases heat insulation effectiveness while preventing print energy diffusion, thereby maintaining recording density. The specific range of 10-30 μm was determined through experimentation to optimize both heat insulation and recording performance.
Solution Approach 2:
The patent uses composite hollow particles consisting of a core shell structure with specific material composition. The hollow particles are composed of polymer materials with controlled wall thickness and internal cavity structure, creating a composite structure that maximizes heat insulation while maintaining appropriate thermal conductivity for recording energy transmission.
2Loss of energy
If hollow particles with small particle diameters are used to enhance heat insulation, then the heat insulation properties improve, but the print image quality deteriorates due to weak cushioning property
Solution Approach 1:
The patent changes the particle diameter parameter from small (1-10 μm) to large (10-30 μm) to provide adequate cushioning property. The larger particles create a more effective cushioning layer that absorbs printing pressure, preventing white spots and ensuring uniform image quality while maintaining heat insulation performance.
3Loss of energy
If thermally expandable resin particles with varying particle diameters (1-25 μm) are used, then the heat insulation properties improve, but the image quality deteriorates due to surface smoothness reduction
Solution Approach 1:
The patent changes the particle diameter parameter to a specific range (10-30 μm) with controlled distribution, eliminating the ultrafine particles (≤2 μm) that cause surface roughness. This parameter optimization ensures both heat insulation effectiveness and surface smoothness for high-quality printing.
Solution Approach 2:
The patent applies local quality control by specifying different particle diameter ranges for different functional requirements. The hollow particles are designed with specific size distribution where larger particles (10-30 μm) provide heat insulation and cushioning, while the exclusion of ultrafine particles maintains surface smoothness. This localized optimization of particle properties resolves the contradiction between heat insulation and image quality.
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 material achieves high sensitivity, clear printed images with less printing omission, and improved halftone printing density with excellent coating surface strength.
Implementation Method 1
the heat insulation properties are insufficient, the print energy tends to diffuse
Implementation Method 2
the coating layer has a weak cushioning property
Data Source
AI summary
There is disclosed a heat-sensitive recording material including an undercoat layer formed on one surface of a support and a heat-sensitive recording layer formed on the undercoat layer. The heat-sensitive recording layer contains a leuco dye and a coloring agent. The undercoat layer contains hollow particles and a binding resin. A maximum particle diameter (D100) of the hollow particles is 10 to 30 μm. A particle diameter (D50) of the hollow particles at cumulative 50 volume % is 4.0 to 15 μm. A ratio D100/D50 of the maximum particle diameter (D100) of the hollow particles to the particle diameter (D50) of the hollow particles at cumulative 50 volume % is 1.8 to 3.0. A volume percentage of the hollow particles having particle diameters of 2.0 μm or less is 1% or less.