Stereoscopic Image Manufacturing via Two-Stage Heating and Foaming Control
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Solution Overview
Problem
Existing methods for manufacturing stereoscopic images struggle to control foamability and achieve sufficient foaming height when producing recorded matters at high speeds, particularly due to issues with foaming promotion layers formed on record media, where solvent evaporation increases viscosity and concentration of foaming agents, leading to inconsistent foaming and shape control.
Innovation Solution
A method involving a first heating step to set the record medium's surface temperature below the foaming start temperature, followed by application of a foaming control liquid using an ink jet recording head, and a second heating step to promote or suppress foaming, ensuring the foaming control liquid spreads and evaporates to control foamability, while maintaining the binder resin in a softened state to prevent hindrance of foaming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a foaming promotion liquid is applied to the record medium and then heating is performed to increase stereoscopic image formation speed, then the foaming speed increases, but the foamability becomes difficult to control and foaming height becomes insufficient
Solution Approach 1:
The heating process is divided into two distinct stages: preheating (first heating unit) and foaming (second heating unit). This segmentation allows independent optimization of each stage - preheating prepares the record medium by raising temperature below the foaming start temperature, while the subsequent foaming stage applies higher temperature to promote controlled foaming. This resolves the contradiction by enabling fast processing without sacrificing foamability control.
Solution Approach 2:
The preheating step performs preliminary action by raising the record medium temperature to a controlled level (below foaming start temperature) before the actual foaming process. This preliminary temperature preparation ensures that when the foaming promotion liquid is applied and second heating occurs, the foaming proceeds controllably with sufficient height, while still maintaining high overall processing speed.
2Productivity
If the record medium is heated to high temperature to promote foaming, then foaming speed increases, but the binder resin hardens and hinders foaming
Solution Approach 1:
The heating process is divided into two distinct stages: preheating (first heating unit) and foaming (second heating unit). This segmentation allows independent optimization of each stage - preheating prepares the record medium by raising temperature below the foaming start temperature, while the subsequent foaming stage applies higher temperature to promote controlled foaming. This resolves the contradiction by enabling fast processing without sacrificing foamability control.
Solution Approach 2:
The temperature parameter is dynamically adjusted in two stages: first heating to a moderate temperature (below foaming start temperature) to soften the binder resin without causing premature hardening, then second heating to higher temperature (at or above foaming temperature) to promote rapid foaming. This parameter change strategy ensures the binder resin remains in a softened state during critical foaming phases while still achieving high foaming speed.
3Productivity
If a foaming promotion layer is formed in advance on the record medium, then manufacturing efficiency improves, but the solvent evaporates and increases viscosity leading to inconsistent foaming
Solution Approach 1:
The preheating step performs preliminary action by raising the record medium temperature to a controlled level (below foaming start temperature) before the actual foaming process. This preliminary temperature preparation ensures that when the foaming promotion liquid is applied and second heating occurs, the foaming proceeds controllably with sufficient height, while still maintaining high overall processing speed.
Solution Approach 2:
The temperature parameter is dynamically adjusted in two stages: first heating to a moderate temperature (below foaming start temperature) to soften the binder resin without causing premature hardening, then second heating to higher temperature (at or above foaming temperature) to promote rapid foaming. This parameter change strategy ensures the binder resin remains in a softened state during critical foaming phases while still achieving high foaming speed.
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
This approach allows for precise control of foamability and achieves a stereoscopic image with sufficient foaming height, even at high production speeds, by selectively promoting or suppressing foaming regions, resulting in consistent and clear stereoscopic images.
Implementation Method 1
a first heating step of heating a record medium including a substrate and a foaming layer that is disposed on the substrate and that contains a foaming material to be foamed due to heat
Implementation Method 2
a foaming control liquid application step of applying a foaming control liquid for controlling foaming of the foaming material to the surface of the record medium heated in the first heating step
Implementation Method 3
a second heating step of heating the record medium provided with the foaming control liquid to form a stereoscopic image
Implementation Method 4
a foaming layer that is disposed on the substrate and that contains a foaming material to be foamed due to heat
Data Source
AI summary
A method for manufacturing a recorded matter having a stereoscopic image includes a first heating step, a foaming control liquid application step, and a second heating step. A surface temperature T0 (° C.) of the record medium before being heated in the first heating step, a surface temperature T1 (° C.) of the record medium after being heated in the first heating step, and a foaming start temperature Tf (° C.) of the foaming material satisfy a relationship represented by Formula (1):T0<T<Tf (1).