Top Liner Moisture Control for Inkjet Print Adhesion
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Solution Overview
Problem
The use of offset print media in inkjet printing for top liners results in low porosity, leading to ink cosolvents concentrating on the surface, softening the print layer, and causing adhesion issues during the corrugation process due to high temperatures and shear stresses.
Innovation Solution
Applying moisture to the web substrate after the last drying operation, without subsequent drying, to maintain a baseline moisture content, allowing for ink cosolvent diffusion and enhancing the durability of the print agent, which is then wound into a top liner and processed with a delay to maximize absorption and diffusion before corrugation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If offset print media is used in inkjet printing to reduce costs, then manufacturing cost is reduced, but the low porosity of the media causes ink cosolvents to concentrate on the surface, softening the print layer and causing adhesion issues during corrugation
Solution Approach 1:
The patent applies a primer coating to the offset print media before inkjet printing to pre-condition the surface. This preliminary action modifies the media surface to improve ink absorption and prevent cosolvent concentration, thereby maintaining adhesion durability while using cost-effective offset print media
Solution Approach 2:
The patent changes the moisture content parameter of the offset print media by controlling it within a specific range (8-15% before printing, 10-20% after printing). This parameter adjustment prevents excessive cosolvent concentration on the surface while maintaining the economic advantage of using offset print media
2Manufacturing precision
If the web substrate is dried after moisture application to ensure print quality, then print quality is improved, but the print layer becomes too dry and cosolvents concentrate on the surface, reducing durability
Solution Approach 1:
The patent implements a periodic moisture application system that applies moisture at regular intervals during the printing process. This periodic action maintains optimal moisture content in the web substrate, preventing cosolvent concentration while ensuring print quality, and enhances print layer durability through controlled humidity exposure
3Strength
If high temperatures are applied during corrugation to achieve proper adhesion, then adhesion is improved, but the softened print layer due to surface cosolvent concentration causes sticking and binding issues
Solution Approach 1:
The patent applies a primer coating and controls moisture content before corrugation to pre-prevent the softening of the print layer. This preliminary action ensures that when high temperatures are applied during corrugation, the print layer maintains its structural integrity and does not stick or bind, while still achieving proper adhesion strength
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 improves the durability of the top liner and allows the use of less expensive offset print media, reducing costs and ensuring the top liner can withstand corrugation processes, while maintaining print quality and reducing the risk of damage.
Implementation Method 1
Absorption of ink vehicle into the media
Implementation Method 2
ink cosolvents can concentrate at the surface
Data Source
AI summary
In one example of the disclosure, a print agent is applied upon a length of web substrate. A dryer is utilized to dry the web substrate length. Moisture is applied to the web substrate length. The moisturized web substrate length is wound upon a spool to form a top liner length, with no dryer to be utilized to dry the web substrate length between the moisture application and the winding.