UV-Curable Inkjet Ink for Electroless Plating
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Solution Overview
Problem
Existing UV-curable inkjet ink compositions face challenges such as premature polymerization in thermal print heads, nozzle clogging, and safety hazards due to organic solvents and vinyl monomers, which limit their use in functional patterning for applications like electroless metal plating and sensor formation.
Innovation Solution
A UV-curable inkjet ink composition comprising a reactive polymer with at least 40 mol% pendant metal complexing water-solubilizing groups and 5 mol% crosslinkable units capable of [2+2] photocycloaddition, along with optional components like humectants, dyes, and surfactants, that remains water-soluble before crosslinking but becomes water-insoluble and permeable after, allowing for stable thermal ejection and electroless plating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If UV-curable inkjet ink compositions containing vinyl monomers and organic solvents are used, then curing capability is achieved, but premature polymerization in thermal print heads occurs and safety hazards arise
Solution Approach 1:
The patent extracts and removes the harmful vinyl monomer components from the inkjet composition while retaining the essential UV-curing capability through alternative chemistry. The composition uses photoinitiators that can cure without traditional vinyl monomers, eliminating the source of premature polymerization and safety hazards while maintaining the desired curing function.
Solution Approach 2:
The patent changes the chemical parameters of the inkjet composition by replacing vinyl monomer-based UV curing systems with alternative photopolymerization systems that use different chemical mechanisms. This parameter change allows curing to occur without the harmful side effects of traditional vinyl monomer systems, including premature polymerization and safety hazards associated with organic solvents.
2Productivity
If thermal DOD print heads are used for high-speed printing, then ejection rates exceed 30 kHz, but the resistive heater decomposes the ink jet ink composition causing nozzle clogging
Solution Approach 1:
The patent changes the thermal stability parameters of the inkjet composition by formulating a composition that remains stable at the high temperatures required for thermal DOD printing. The alternative photopolymerization system and solvent selection ensure the composition does not decompose at heater temperatures, preventing kogation and nozzle clogging while maintaining high ejection rates.
Solution Approach 2:
The patent uses a water-based composition that is inexpensive and can be readily replaced if needed, rather than using expensive specialized formulations. The water-based system provides adequate performance for thermal printing applications without requiring complex or costly additives that would increase formulation complexity.
3Use of energy by moving object
If aqueous-based inks are used for thermal ejection, then energy transfer efficiency is improved, but fine mist formation creates health and safety hazards
Solution Approach 1:
The patent converts the potential harm of fine mist formation into a benefit by using water as the base solvent. While water-based inks do form mist during thermal ejection, water is not flammable or toxic like organic solvents, so the mist poses minimal health and safety hazards. The high energy transfer efficiency of water is retained while the harmful effects are eliminated through the benign nature of the solvent.
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 composition enables reliable inkjet printing of functional patterns with improved stability and safety, enabling high-resolution, electrically conductive metal patterns and antimicrobial properties without nozzle clogging or safety hazards.
Implementation Method 1
at least 5 mol % of recurring units comprising a pendant group capable of crosslinking via [2+2] photocycloaddition
Implementation Method 2
They also require the ink jet ink composition to come into contact with a resistive heater that vaporizes enough ink jet ink composition to form a vapor bubble
Implementation Method 3
a resistive heater that vaporizes enough ink jet ink composition to form a vapor bubble capable of ejecting the remaining ink jet ink composition
Implementation Method 4
at least 40 mol % of recurring units comprising pendant metal complexing water-solubilizing groups
Data Source
AI summary
A method for forming an ink jet image on a substrate includes ink jetting an ink jettable and UV-curable composition onto the substrate in an imagewise fashion to form an ink jetted image on the substrate. The ink jettable and UV-curable composition includes: a reactive polymer having: (a1) or (a2) recurring units having pendant metal complexing water-solubilizing groups, (b) at least 5 mol % of recurring units having a pendant group capable of crosslinking via [2+2] photocycloaddition, and optionally (c) at least 1 mol % of recurring units including a pendant amide, hydroxyl, or lactam group, or a pendant precursor moiety for the pendant amide, hydroxyl, or lactam group. The ink jetted image is cured to form a UV-cured ink jet image on the substrate. The ink jettable and UV-curable composition can also include metal nanoparticles or reducible metal ions that can serve as catalytic sites for electroless plating.