Thermal Reversible Viscosity Control in Multi-Layer Coating
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Solution Overview
Problem
Conventional methods for manufacturing information recording materials with multi-layer coats face issues such as inter-layer mixing and uneven coating quality due to viscosity changes during the application process, particularly in thermosensitive and inkjet recording materials, which affect the performance and productivity of these materials.
Innovation Solution
A method involving the use of coating liquids containing components that increase viscosity through thermal reversible reactions, such as polyvinyl alcohol (PVA) and boric acid, which are controlled in temperature and pH to prevent viscosity increase during application and allow for post-application film hardening, thereby preventing inter-layer mixing and ensuring stable coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a simultaneous multi-layer coating process is used to improve productivity, then coating efficiency is improved, but inter-layer mixing occurs due to viscosity changes
Solution Approach 1:
The patent applies parameter changes by controlling temperature and pH to regulate viscosity changes. Specifically, the coating liquid's viscosity is increased by lowering temperature or adjusting pH after application, but during the coating process, parameters are maintained to keep viscosity stable, preventing inter-layer mixing while enabling simultaneous multi-layer coating.
Solution Approach 2:
The patent implements preliminary action by pre-adjusting the coating liquid's temperature and pH before application to ensure stable viscosity during the coating process. This preliminary control prevents viscosity changes that would cause inter-layer mixing, allowing high-speed simultaneous multi-layer coating to proceed without quality degradation.
2Manufacturing precision
If coating liquid viscosity increases over time to prevent inter-layer mixing, then coat quality is improved, but coating application becomes difficult
Solution Approach 1:
The patent applies periodic action by controlling viscosity changes to occur at specific stages: during coating application, temperature and pH are maintained to keep viscosity low and stable for easy application; after application, temperature is lowered or pH is adjusted to increase viscosity and prevent inter-layer mixing. This staged control separates the coating and prevention functions in time.
Solution Approach 2:
The patent implements dynamics by making the coating liquid's viscosity dynamic rather than static. The viscosity is kept stable during application through temperature and pH control, then increased after application through the same control mechanisms. This dynamic adjustment allows the liquid to be easily applied then effectively fixed, resolving the contradiction between application ease and coat 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
This approach enables the production of information recording materials with improved performance and reduced material thickness by preventing inter-layer mixing and maintaining coating quality, while allowing for precise control of the film hardening reaction to optimize the coating process.
Implementation Method 1
coating liquids containing components which, when brought into contact or are mixed with each other, make the coating liquids increase in viscosity, preferably wherein the plurality of components react with each other and increase in viscosity by being brought into contact or mixed with each other and the reaction is a thermal reversible reaction
Implementation Method 2
at least one coating liquid out of the plurality of coating liquids contains a plurality of components which, when brought into contact or are mixed with each other, make the coating liquids increase in viscosity
Implementation Method 3
the plurality of components react with each other and increase in viscosity by being brought into contact or mixed with each other
Data Source
AI summary
Normal simultaneous multi-layer coating can be accomplished without allowing the coating liquids to increase in viscosity before and during their application, and inter-layer mixing can be prevented by increasing the viscosity after the application. In a method of manufacturing an information recording material in which at least one out of a plurality of layers formed by simultaneous multi-layer application of a plurality of coating liquids over a running supporting base 14 with a slide bead coating device 16 is an information recording layer, and the multi-layer coats so formed are dried by a drying device 20, at least one of the plurality of coating liquids contains PVA and boric acid whose mutual contact or mixing causes the coating liquids to increase in viscosity.