Thermal Transfer Support with Density-Graded Polyolefin Layers
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Solution Overview
Problem
The existing thermal transfer image-receiving sheets with polyolefin resin layers suffer from insufficient texture and curl stability, especially under high temperature and high humidity conditions, due to the adhesion issues between the polyolefin resin layers and the dye-receiving layer.
Innovation Solution
A thermal transfer image-receiving sheet is designed with a porous layer, a first polyolefin resin layer of density 0.93 g/cm3 or less, and a second polyolefin resin layer of greater than 0.93 g/cm3, where the second layer is 1 to 5 times thicker than the first, and both layers are formed using extrusion lamination methods to improve curl stability and texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polyolefin resin layers are laminated using adhesive layers, then the layers are bonded together, but the texture of the print surface is deteriorated
Solution Approach 1:
The patent uses a porous polymer film as an intermediary layer between the substrate and polyolefin resin layers. This porous film enables adhesive bonding without requiring additional adhesive layers that would deteriorate the print surface texture. The porous structure allows for effective adhesion while maintaining surface quality.
Solution Approach 2:
The patent employs a porous polymer film with specific porosity (30-80%) to achieve both adhesion and surface texture requirements. The porous structure provides bonding capability through surface area increase and mechanical interlocking, while the film itself maintains the desired print surface texture without needing additional adhesive coatings.
2Stability of the object's composition
If polyolefin resin layers are used to prevent curl, then curl resistance is improved, but the texture and smoothness of the print surface are insufficient
Solution Approach 1:
The patent segments the functional layers into distinct components: a substrate layer for structural support and curl resistance, and a separate porous polymer film layer for providing print surface texture. This segmentation allows each layer to optimize its specific function without compromising the other.
Solution Approach 2:
The porous polymer film with controlled porosity (30-80%) provides the necessary surface texture and smoothness for high-quality printing, while the underlying substrate layer maintains curl resistance. The porous structure enables this dual functionality by separating the textural properties from the structural stability requirements.
3Strength
If adhesive layers are used to bond polyolefin resin layers, then bonding strength is achieved, but the texture quality is reduced under high temperature and humidity
Solution Approach 1:
The porous polymer film serves as a mediator that provides inherent bonding capability through its porous structure, eliminating the need for adhesive layers that would compromise texture quality under high temperature and humidity conditions. The porous film maintains both adhesion and surface quality in challenging environmental conditions.
Data Source
AI summary
Provided is a support for a thermal transfer image-receiving sheet, capable of obtaining a thermal transfer image-receiving sheet that has favorable stability against curl and is excellent in the texture of a print surface in the case of print under the environmental conditions of high temperature and high humidity. A support for a thermal transfer image-receiving sheet according to the present invention includes a porous layer composed of a porous film, a first polyolefin resin layer, a substrate layer, and a second polyolefin resin layer that are layered in the order mentioned, in which the first polyolefin resin layer has a density of 0.93 g/cm3 or less; and the second polyolefin resin layer has a density of more than 0.93 g/cm3.