Thermal Transfer Support Lamination Roller Spacing Control
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Solution Overview
Problem
Existing methods for producing thermal transfer image-receiving sheets fail to achieve sufficient surface smoothness and adhesiveness between the substrate and porous film, leading to suboptimal print texture and adhesion.
Innovation Solution
A method involving the lamination of a substrate and porous film using a melt-extruded resin, where the substrate and porous film are passed through a pair of rollers with a regulated spacing to ensure optimal adhesiveness and texture, with specific thickness and roughness conditions for the adhesive and porous layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the substrate and porous film are passed through rollers with large spacing, then the porous film structure is preserved, but the adhesiveness between substrate and porous film is insufficient
Solution Approach 1:
The invention changes the spacing parameter between rollers to a specific range (50-200 μm) that is smaller than conventional large spacing but larger than the total thickness of substrate and porous film. This parameter optimization allows the porous film structure to be preserved while achieving sufficient adhesiveness through controlled compression during the lamination process.
Solution Approach 2:
The invention applies local quality by creating a resin layer with specific thickness (5-50 μm) between the substrate and porous film through controlled roller spacing. This localized resin application ensures adequate adhesiveness at the interface while maintaining the overall porous structure of the film.
2Reliability
If the roller spacing is reduced to improve adhesiveness, then the bonding between layers is enhanced, but the texture of the print surface deteriorates
Solution Approach 1:
The invention optimizes the roller spacing parameter to fall within 50-200 μm, which is sufficient to create adhesive bonding but not so small as to crush the porous film structure. This parameter control ensures both good adhesiveness and preserved surface texture for printing.
Solution Approach 2:
The invention uses partial action by applying resin only in the gap between rollers rather than complete coating. The resin layer thickness (5-50 μm) is controlled to be sufficient for adhesion but not excessive, avoiding over-compression that would damage the porous film structure and print surface texture.
3Ease of manufacture
If conventional melt extrusion coating is used, then the production process is simple, but the surface smoothness is insufficient
Solution Approach 1:
The invention introduces a resin layer as an intermediary between the substrate and porous film, created through controlled lamination with regulated roller spacing. This intermediate resin layer provides the necessary surface smoothness while maintaining the simplicity of the melt extrusion coating process.
Solution Approach 2:
The invention changes the roller spacing parameter to a specific optimized range (50-200 μm) that produces sufficient surface smoothness without requiring complex additional processing steps. This parameter optimization achieves better surface quality while maintaining production process simplicity.
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 method enhances the adhesiveness between the substrate and porous film while maintaining the texture of the print surface, improving the overall quality of the thermal transfer image-receiving sheet.
Implementation Method 1
laminating a substrate and a porous film with a melt-extruded resin
Implementation Method 2
laminating a substrate and a porous film with a melt-extruded resin while passing the substrate and the porous film through a portion between rollers in a pair
Data Source
AI summary
Provided is a method for producing a support for a thermal transfer image-receiving sheet, including laminating a substrate and a porous film by a melt-extruded resin while passing the substrate and the porous film through a portion between rollers in a pair, wherein a thermal transfer image-receiving sheet excellent in adhesiveness between the substrate and the porous film and excellent in the texture of a print surface can be obtained. A method for producing a support for a thermal transfer image-receiving sheet according to the present invention is a method for producing a support for a thermal transfer image-receiving sheet including a substrate layer composed of a substrate, an adhesive layer composed of a melt-extruded resin, and a porous layer including a porous film that are layered in the order mentioned, in which the substrate and the porous film are laminated by the melt-extruded resin while passing the substrate and the porous film through the portion between rollers in a pair having a spacing with a distance d; and a difference (d−h) between the distance d which is the spacing between the rollers in the pair and the total thickness h of the substrate layer, the adhesive layer, and the porous layer is −50 μm or more and 50 μm or less.