Thermal Transfer Sheet with Controlled Shearing Stress
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Solution Overview
Problem
Current thermal transfer sheets face issues with thermal fusion between the transfer receiving article and the thermal transfer sheet, leading to printer jams and transfer layer fall-off, especially when high energy is applied, and existing countermeasures are insufficient in preventing these issues.
Innovation Solution
A thermal transfer sheet with a substrate and a transfer layer having a critical shearing stress of 0.9×10^8 N/m^2 or more and a release force of 7.5×10^-2 N/cm or less, measured using specific conditions, to prevent thermal fusion and transfer layer fall-off during high-energy applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high energy is applied to transfer the transfer layer onto the transfer receiving article, then transfer efficiency is improved, but thermal fusion between the transfer receiving article and the thermal transfer sheet occurs
Solution Approach 1:
The patent modifies the physical and chemical parameters of the transfer layer by controlling the glass transition temperature (Tg) of the binder resin to be 50°C or higher, and adjusting the weight average molecular weight to 10,000 or higher. These parameter changes enable the transfer layer to maintain adequate adhesion to the substrate during high-energy transfer processes while allowing controlled release onto the receiving article, thereby resolving the contradiction between transfer efficiency and thermal fusion prevention.
Solution Approach 2:
The patent employs composite material design by formulating the transfer layer with specific binder resins that combine high Tg characteristics with appropriate molecular weights. This composite approach creates a transfer layer that exhibits dual behavior: strong adhesion to the substrate under high energy conditions and controlled release properties, thus preventing thermal fusion while maintaining high transfer efficiency.
2Stability of the object's composition
If the transfer layer is firmly adhered to the substrate, then transfer layer stability is improved, but release force increases causing transfer layer fall-off
Solution Approach 1:
The patent achieves the balance between transfer layer stability and release force by precisely controlling the binder resin parameters: glass transition temperature (Tg) of 50°C or higher ensures firm adhesion and stability, while weight average molecular weight of 10,000 or higher provides controlled release characteristics. This parameter optimization allows the transfer layer to remain stable on the substrate during handling and transfer, yet release cleanly without fall-off.
3Speed
If thermal energy is increased to melt or soften the transfer layer for hot release, then release speed is improved, but unintended thermal fusion occurs
Solution Approach 1:
The patent addresses the hot release process by setting the binder resin's glass transition temperature (Tg) to 50°C or higher. This parameter ensures that the transfer layer requires sufficient thermal energy for rapid release while maintaining stability against unintended thermal fusion with the substrate. The controlled Tg range enables the transfer layer to respond appropriately to heating during release while preventing excessive softening that would cause thermal fusion.
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 thermal transfer sheet effectively suppresses thermal fusion and transfer layer fall-off, ensuring reliable operation even under high-energy conditions, maintaining print quality and preventing printer jams.
Implementation Method 1
applying thermal energy to the thermal transfer sheet while the transfer receiving article and the transfer layer of the thermal transfer sheet are kept in close contact to each other to transfer the transfer layer onto the transfer receiving article
Implementation Method 2
hot release-type printers that apply thermal energy to a thermal transfer sheet to melt or soften the transfer layer and release only the transfer layer transferred on a transfer receiving article from the thermal transfer sheet
Data Source
AI summary
A thermal transfer sheet includes a transfer layer on a substrate. The transfer layer has one or more layers. The critical shearing stress of the transfer layer is within the range of 0.9×108 N/m2-2×108 N/m2. The transfer layer has a release force of 7.5×10−2 N/cm or less, while the transfer layer is continuously transferred onto a transfer receiving article by use of a thermal printer under conditions including an applied energy of 0.127 mJ/dot and a conveying speed for the thermal transfer sheet of 84.6 mm/sec. The transfer layer transferred onto the transfer receiving article is released from the thermal transfer sheet at a release angle of 50°.