Thermal Transfer Image-Receiving Sheet Curl Prevention
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Solution Overview
Problem
Conventional thermal transfer image-receiving sheets suffer from concave curl generation, which degrades image quality and makes them difficult to cut to desired sizes, especially under varying environmental conditions.
Innovation Solution
A thermal transfer image-receiving sheet comprising a first extrusion resin layer, a substrate, a second extrusion resin layer, a porous layer, and a receiving layer, with specific thickness ratios and materials that enhance image density and prevent concave curl, including olefin resins and coated paper substrates with defined bending resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional thermal transfer image-receiving sheet is used, then high-density image formation is achieved, but concave curl generation occurs over time due to environmental factors
Solution Approach 1:
The patent employs a composite structure consisting of a substrate, first extrusion resin layer, second extrusion resin layer, porous layer, and receiving layer. Each layer is composed of specific materials with defined properties (substrate bending resistance 1600-2500 mg, extrusion resin layers with specific thickness ratios). This multi-layer composite construction allows the sheet to maintain high-density image formation capability while the specific combination of layers with controlled thickness ratios prevents concave curl generation by balancing internal stresses and providing dimensional stability against environmental variations.
Solution Approach 2:
The patent specifies precise parameter ranges to resolve the contradiction: the ratio of (second extrusion resin layer thickness + porous layer thickness) to first extrusion resin layer thickness is controlled at 1.05-1.40, substrate bending resistance is set at 1600-2500 mg, and coated layer thickness ratio is maintained at 5-20%. By optimizing these parameters within defined ranges, the sheet achieves both high-density image formation and resistance to concave curl, transforming the problematic environmental sensitivity into a controlled, stable performance.
2Ease of operation
If the receiving layer is made thinner to improve cutting ease, then easiness of cutting is enhanced, but image density and quality deteriorate
Solution Approach 1:
The patent divides the image-receiving sheet into five distinct functional layers: substrate, first extrusion resin layer, second extrusion resin layer, porous layer, and receiving layer. This segmentation allows each layer to be optimized for its specific function - the receiving layer can be kept thin for easy cutting while the underlying porous layer and extrusion resin layers provide structural support, dimensional stability, and image reception capability. The receiving layer thickness is controlled at 3-15 μm for cuttability, while the total sheet structure maintains sufficient strength and image density through the combined layers.
Solution Approach 2:
Different regions and layers of the sheet are assigned different properties tailored to local requirements. The receiving layer (3-15 μm) is optimized for thinness and cuttability, while the porous layer provides intermediate support and the extrusion resin layers provide structural integrity. The substrate with bending resistance of 1600-2500 mg provides overall stability. This local optimization allows the receiving layer to be thin for easy cutting without compromising overall image density and quality, as each layer contributes its specific local function to the whole system.
3Stability of the object's composition
If the substrate bending resistance is increased to prevent curl, then concave curl generation is reduced, but the sheet becomes more difficult to cut and process
Solution Approach 1:
The patent balances the substrate bending resistance within a dynamic range of 1600-2500 mg rather than using a fixed high value. This dynamic optimization allows the substrate to provide sufficient curl resistance (preventing concave curl) while maintaining cuttability. The specific range was determined to be the optimal balance point where the substrate is stiff enough to prevent environmental-induced curling but not so stiff as to prohibit cutting and processing operations.
Solution Approach 2:
The patent specifies precise parameter ranges to resolve the contradiction: the ratio of (second extrusion resin layer thickness + porous layer thickness) to first extrusion resin layer thickness is controlled at 1.05-1.40, substrate bending resistance is set at 1600-2500 mg, and coated layer thickness ratio is maintained at 5-20%. By optimizing these parameters within defined ranges, the sheet achieves both high-density image formation and resistance to concave curl, transforming the problematic environmental sensitivity into a controlled, stable performance.
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 solution enables high-density image formation with improved easiness of cutting and reduced concave curl generation, maintaining image quality and usability.
Implementation Method 1
a porous layer... wherein the ratio of the total of the thickness of the second extrusion resin layer and the thickness of the porous layer to the thickness of the first extrusion resin layer
Implementation Method 2
the sublimation dye in the dye layer is thus transferred to the receiving layer of the thermal transfer image-receiving sheet to form an image
Data Source
AI summary
[Problem] To provide a thermal transfer image-receiving sheet that enables a high-density image to be formed on the receiving layer, has high easiness of cutting, and in addition, has high concave curl generation preventiveness.[Solution] A thermal transfer image-receiving sheet according to the present invention is characterized by including a first extrusion resin layer, a substrate, a second extrusion resin layer, a porous layer, and a receiving layer, wherein the ratio of the total of the thickness of the second extrusion resin layer and the thickness of the porous layer to the thickness of the first extrusion resin layer (the total of the thickness of the second extrusion resin layer and the thickness of the porous layer/the thick of the first extrusion resin layer) is 1.05 or more and 1.40 or less, and the substrate has a bending resistance of 1600 mg or more and 2500 mg or less.