UV-Curable Ink Set Composition for Laminate Adhesion and Water Resistance
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Solution Overview
Problem
Existing inkjet technologies for manufacturing decorative laminates, particularly LVT, face challenges with adhesion and water resistance, which are not adequately addressed by current aqueous and UV curable systems, leading to issues like swelling and adhesion failures in humid environments.
Innovation Solution
An ink set comprising pigmented free radical curable inkjet inks and a free radical curable liquid with specific polymerizable compositions, including monofunctional and polyfunctional compounds, enhances adhesion and water resistance by minimizing the use of color pigments and dispersants, thereby improving laminate bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aqueous inkjet technologies are used to improve adhesion, then adhesion is improved, but water resistance is reduced due to swelling of hydrophilic layers
Solution Approach 1:
The patent changes the chemical composition parameters of the inkjet ink by incorporating polymerizable compounds (acrylates, methacrylates, vinyl esters, vinyl ethers) that can undergo photopolymerization. This transforms the ink from a hydrophilic aqueous formulation to a hydrophobic crosslinked polymer network after UV curing, simultaneously achieving adhesion and water resistance
Solution Approach 2:
The patent creates a composite material system combining organic polymerizable compounds with inorganic fillers and pigments in a reactive ink formulation. The resulting cured ink layer exhibits composite properties: adhesion from polymer-substrate bonding, water resistance from crosslinked network structure, and optical properties from pigment dispersion
2Reliability
If UV curable inkjet systems are used, then water resistance is improved, but adhesion remains insufficient without additional measures
Solution Approach 1:
The patent merges the adhesion promotion function and water resistance function into a single integrated UV curable ink formulation. The polymerizable compounds provide both adhesion to the substrate and water resistance through crosslinking, eliminating the need for separate adhesive layers or primers
Solution Approach 2:
The ink formulation contains its own adhesion-promoting and water-resistant properties inherently through the polymerizable compound composition. The ink self-cures upon UV exposure to form a crosslinked network that simultaneously provides adhesion and water resistance without requiring additional processing steps or materials
3Strength
If additional adhesive layers are applied to improve adhesion, then adhesion is improved, but organic solvents are required which pose safety risks
Solution Approach 1:
The patent extracts and eliminates organic solvent components from the adhesive system by using water-based or solvent-free polymerizable compound formulations. The adhesive function is achieved through photopolymerization of reactive monomers and oligomers rather than through organic solvent-based adhesives, removing the safety hazards associated with organic solvents
Solution Approach 2:
The patent replaces expensive and hazardous organic solvent-based adhesive layers with a simpler, safer UV curable ink formulation that cures rapidly upon UV exposure. The short curing time and elimination of solvent evaporation make the process safer and more environmentally friendly
4Strength
If UV curing is carried out to incomplete extent during lamination, then adhesion is improved, but the system becomes vulnerable to scratches and dust
Solution Approach 1:
The patent applies partial curing during lamination to maintain adhesion flexibility, then completes the curing process in a subsequent step to achieve full crosslinking density. This two-stage curing approach allows the ink to be sufficiently cured for adhesion while remaining processable during lamination, and finally fully cured to provide scratch and dust resistance
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 ink set achieves superior adhesion and water resistance in decorative laminates, ensuring durability in humid conditions without the need for organic solvents, thus overcoming the limitations of previous technologies.
Implementation Method 1
pigmented free radical curable inkjet inks and a free radical curable liquid... UV curable inkjet inks... UV curing is carried out
Data Source
AI summary
An ink set for manufacturing decorative laminates including pigmented free radical curable inkjet inks and a free radical curable liquid, wherein the pigmented free radical curable inkjet inks include a colour pigment and a polymerizable composition containing 10 to 90 wt % of one or more monofunctional polymerizable compounds; wherein the free radical curable liquid includes a polymerizable composition containing 15 wt % or more of polyfunctional polymerizable compounds and 15 wt % or more of a specific monofunctional polymerizable compound; and wherein all weight percentages wt % are based upon the total weight of the polymerizable composition in the pigmented free radical curable inkjet ink or the polymerizable composition in the free radical curable liquid.