Transfer Barrier Layer for High Gloss Inkjet Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing printed products with inkjet inks and acidic precoat layers result in unsatisfactory gloss values when varnished with water-based varnishes, particularly in packaging applications.
Innovation Solution
Applying an at least partially dried barrier layer to the precoat printed with inkjet ink before varnishing, which is produced separately on a support and transferred to the substrate, allowing for high gloss values without significantly altering the thickness or haptics of the printed products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an acidic precoat layer is used to improve print quality, then the definition of printing dots is improved, but the gloss values of water-based varnish are reduced
Solution Approach 1:
A barrier layer is introduced as an intermediary between the acidic precoat layer and the water-based varnish. This barrier layer has neutral or basic pH properties that neutralize the acidic precoat surface, creating a compatible interface for the varnish application and enabling high gloss values while maintaining the benefits of the acidic precoat for print quality
Solution Approach 2:
The coating system is segmented into distinct functional layers: the acidic precoat layer for print quality enhancement, the neutral barrier layer for pH balancing and compatibility, and the water-based varnish for gloss and protection. This segmentation allows each layer to perform its specific function without interfering negatively with others
2Illumination intensity
If a barrier layer is applied to neutralize acidic precoat, then varnish gloss values are improved, but the thickness and weight of the printed product increase
Solution Approach 1:
The barrier layer is formulated as a thin film or shell that provides the necessary pH neutralization and compatibility functions with minimal thickness. This thin-film approach ensures that the barrier layer adds negligible weight and volume to the printed product while effectively preventing the acidic precoat from negatively affecting the varnish gloss
Solution Approach 2:
The barrier layer is designed with optimized physical and chemical parameters, including controlled thickness, appropriate viscosity, and suitable drying characteristics. By carefully adjusting these parameters, the barrier layer achieves maximum effectiveness in neutralizing the acidic precoat while minimizing its impact on the overall product dimensions and weight
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 method achieves high gloss values for printed products while maintaining minimal thickness and weight changes, enabling the use of conventional printing presses and traditional precoats and varnishes.
Implementation Method 1
drying the barrier composition at least partially
Implementation Method 2
drying the interlayer composition to obtain an interlayer on the substrate
Implementation Method 3
drying the image to form a dried printed image
Data Source
AI summary
A printed product is produced by providing a substrate, producing at least one interlayer on the substrate, printing a printed image onto the interlayer, and forming a barrier layer on the printed image. The barrier layer is provided on the printed image by applying a barrier composition to at least one carrier, at least partially drying the barrier layer and transferring it to the printed image. Preferred substrates have an acidic precoat layer as an interlayer. Such substrates can then be varnished with glossy varnishes, to achieve particularly high gloss values.