DESC:FIELD
The present disclosure relates to the field of graphics and decals.
DEFINITION
As used in the present disclosure, the following term is generally intended to have the meaning as set forth below, except to the extent that the context in which it is used, indicates otherwise.
Water slide decals – The term “water slide decals” refers to thin, transferable images or designs that are printed on a special paper with a water-activated adhesive backing, used for decorating surfaces such as ceramics, glass, plastic, metal, and even nails or model kits.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Typically, decals are widely used to enhance the appearance of vehicles such as bicycles, motorcycles, cars, and transport vehicles, which positively impacts sales. Decals are also popular in aerospace, electronics, sports equipment, medical devices, and musical instruments, in addition to the automotive sector. The decal market, which involves printing, creating, and distributing these graphics, is growing. Typically made from vinyl substrates, decals provide a customizable look to vehicles. The industry uses precise cutting techniques and weather-resistant inks to create durable, high-quality decals that withstand sunlight, temperature changes, and precipitation. Vinyl decals adhere firmly to vehicle surfaces without damaging the paint. Moreover, vinyl-based decals have been the standard in the automotive market for many years.
However, with increasing environmental pollution, governments are imposing strict regulations on industries to adopt environmentally friendly processes and technologies. The use of vinyl, a form of plastic, in graphics and decals contributes to pollution, affecting water, land, and air. The polyvinyl chloride (PVC) substrate, a primary component of vinyl decals, is severely damaging to the environment due to its toxicity and non-biodegradability. Further, the ink system used in these decals is also based on PVC resin to ensure proper adhesion and durability. Furthermore, the plastic film used for lamination and packaging during transport is non-renewable and non-biodegradable. Disposing of these materials through incineration releases harmful substances that significantly impacts the environment. Additionally, the production of vinyl decals generates substantial waste from non-printed materials, exacerbating the environmental impact.
Further, the life cycle of PVC involves the release of toxic chlorine-based chemicals, resulting in highly toxic and carcinogenic by-products such as dioxins and polychlorinated biphenyls (PCBs). Improper disposal via incineration releases these toxic chemicals into the environment. PVC also contributes to greenhouse gas emissions, which further exacerbates the environmental burden by depleting the ozone layer. As PVC is not easily biodegradable, it poses long-term environmental risks, making its disposal a significant concern.
Another concern regarding vinyl decals is their outdoor durability, which is crucial for vehicle applications. However, standard vinyl substrates frequently exhibit inadequate performance in this aspect. Their durability depends on the quality, thickness, and UV resistance of the PVC material. Extreme weather conditions can further diminish their performance.
Although water-slide decals are environment friendly, traditional methods for producing them often involve the use of solvents and water-activated adhesives that can be inconsistent in adhesion. Such processes may result in decals that are prone to smudging or premature degradation, leading to issues with durability and long-term performance.
Therefore, there is felt a need to provide a process for the preparation of water-slide decals that can mitigate the drawbacks mentioned hereinabove or at least provide an alternative solution.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure is to ameliorate one or more problems of the background or to at least provide a useful alternative.
An object of the present disclosure is to provide a process for the preparation of a water-slide decal.
Another object of the present disclosure is to provide a process for the preparation of a water-slide decal that utilizes a diverse range of ink and varnish systems that are PVC-free.
Still another object of the present disclosure is to provide a process for the preparation of a water-slide decal that reduces environmental impact.
Yet another object of the present disclosure is to provide a process for the preparation of a water-slide decal that is polyvinyl chloride (PVC)-free.
Still another object of the present disclosure is to provide a process for preparing a water-slide decal that provides a diverse range of ink and varnish systems for decal applications.
Yet another object of the present disclosure is to provide a process for the preparation of a water-slide decal that ensures lightfastness and durability of the decal ink, especially for metallic and non-metallic pigments.
Still another object of the present disclosure is to provide a water slide decal.
Yet another object of the present disclosure is to provide a process for the preparation of a water-slide decal that demonstrates comparative performance with existing decal application methods.
Still another object of the present disclosure is to provide a process for application of a water-slide decal on multiple types of surfaces that caters to multi-surface compatibility, including a plastic surface, a metal surface, a wood surface, a glass surface, and a ceramic surface.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
In an aspect, the present disclosure relates to a process for the preparation of a water-slide decal, the process comprising the following steps:
a. coating a water slide paper having a predetermined weight by an adhesive layer of a predetermined thickness to obtain a coated water slide paper;
b. screen printing a first ink on the coated water slide paper with a first predetermined mesh size, followed by drying under infrared radiation at a predetermined temperature for a first predetermined time period to obtain a first printed substrate;
c. screen printing a predetermined pattern using a second ink on the first printed substrate with a second predetermined mesh size, followed by drying under infrared radiation at the predetermined temperature for the first predetermined time period to obtain a second printed substrate;
d. screen printing an overprint varnish over the second printed substrate with a third predetermined mesh size, followed by drying under infrared radiation at the predetermined temperature for a second predetermined time period to obtain a varnished substrate; and
e. screen printing a temporary peelable varnish on the varnished substrate with a fourth predetermined mesh size, followed by drying at a temperature in the range of 20 °C to 40 °C for a time period in the range of 12 hours to 30 hours to obtain the water slide decal.
In an embodiment of the present disclosure, the water slide paper is selected from glucose based water slide paper and dextrose-based water slide paper.
In an embodiment of the present disclosure, the predetermined weight of the paper is in the range of 165 gsm to 175 gsm.
In an embodiment of the present disclosure, the adhesive is a water-soluble glucose-based adhesive selected from a-D-glucose based adhesive and ß-D-glucose based adhesive.
In an embodiment of the present disclosure, the predetermined thickness of the adhesive layer is in the range of 4 µm to 18 µm.
In an embodiment of the present disclosure, the first predetermined mesh size is in the range of 70 TPI to 90 TPI.
In an embodiment of the present disclosure, the second predetermined mesh size is in the range of 80 TPI to 110 TPI.
In an embodiment of the present disclosure, the third predetermined mesh size is in the range of 60 TPI to 90 TPI.
In an embodiment of the present disclosure, the fourth predetermined mesh size is in the range of 20 TPI to 30 TPI.
In an embodiment of the present disclosure, the predetermined temperature is in the range of 50 °C to 90 °C.
In an embodiment of the present disclosure, the first predetermined time period is in the range of 1 minute to 10 minutes.
In an embodiment of the present disclosure, the second predetermined time period is in the range of 12 minutes to 40 minutes.
In an embodiment of the present disclosure, the first ink is a white ink and the second ink is a color ink and are at least one selected from the group consisting of a solvent-based ink, a solvent-based UV hybrid ink, a solvent-based LED hybrid ink, a water-based ink, a UV-water-based ink, a LED-water-based ink, a non-solvent UV-based ink and a non-solvent LED-based ink. In an embodiment of the present disclosure, the first ink comprises:
i. a first pigment in an amount in the range of 20 mass% to 50 mass%;
ii. a first resin in an amount in the range of 10 mass% to 50 mass%;
iii. a first fluid medium in an amount in the range of 30 mass% to 70 mass%;
iv. a first plasticizer in an amount in the range of 1 mass% to 3 mass%;
v. a first extender in an amount in the range of 2 mass% to 7 mass%; and
vi. a first levelling additive in an amount in the range of 0.5 mass% to 5 mass%,
wherein the mass% of each component is with respect to the total mass of the first ink composition.
In an embodiment of the present disclosure, the second ink comprises:
i. a second pigment in an amount in the range of 5 mass% to 35 mass%;
ii. a second resin in an amount in the range of 10 mass% to 50 mass%;
iii. a second fluid medium in an amount in the range of 30 mass% to 70 mass%;
iv. a second plasticizer in an amount in the range of 1 mass% to 3 mass%;
v. a second extender in an amount in the range of 0.4 mass% to 2 mass%; and
vi. a second levelling additive in an amount in the range of 0.5 mass% to 5 mass%,
wherein the mass% of each component is with respect to the total mass of the second ink composition.
In an embodiment of the present disclosure, the first pigment is rutile titanium dioxide (TiO2).
In an embodiment of the present disclosure, the first resin is at least one selected from the group consisting of acrylic resin, aliphatic polyurethane resin, and urethane polyester copolymer.
In an embodiment of the present disclosure, the first fluid medium is at least one selected from the group consisting of C9 aromatic solvents, 2-butoxy ethanol, cyclohexanone mixture, butyl carbitol, 1-methoxy-2-propanol, ethyl hexyl acetate, diethylene glycol diethyl ether (DEEG), gamma butyrolactone, propylene carbonate, dimethyl ester, dibasic ester, isopropyl acetoacetate, and derivatives of dibasic ester.
In an embodiment of the present disclosure, the first plasticizer is at least one selected from the group consisting of di-octyl maleate, ethyl hexyl adipate, and polylactic acid.
In an embodiment of the present disclosure, the first extender is at least one selected from the group consisting of barium sulphate, aluminium silicate, talc, and calcium carbonate.
In an embodiment of the present disclosure, the first levelling additive is at least one selected from the group consisting of polymethylalkylsiloxane, polyacrylate (silicon and fluorine free), and polyether (silicon and alkylphenol ethoxylates free).
In an embodiment of the present disclosure, the second pigment is at least one selected from the group consisting of pyrazolone orange , naphthol red AS, 3-hydroxy-4-[(2-methyl-5-nitrophenyl)azo]-N-(2-methylphenyl)-2-naphthalenecarboxamide , phthalocyanine pigment , octanoic acid , copper phthalocyanine green , 2,9-dimethylquinacridone , carbazole dioxazine violet, carbon black, vermillion red, emerald green, aluminium pigments, bronze pigments, vacuum metallized pigments, and encapsulated metallics pigments.
In an embodiment of the present disclosure, the second resin is at least one selected from the group consisting of acrylic resin, aliphatic polyurethane resin, and urethane polyester copolymer.
In an embodiment of the present disclosure, the second fluid medium is at least one selected from the group consisting of C9 aromatic solvents, 2-butoxy ethanol, cyclohexanone mixture, butyl carbitol, 1-methoxy-2-propanol, ethyl hexyl acetate, diethylene glycol diethyl ether (DEEG), gamma butyrolactone, propylene carbonate, dimethyl ester, di-basic ester, isopropyl acetoacetate, and derivatives of dibasic ester.
In an embodiment of the present disclosure, the second plasticizer is at least one selected from the group consisting of di-octyl maleate, ethyl hexyl adipate, and polylactic acid.
In an embodiment of the present disclosure, the second extender is at least one selected from the group consisting of barium sulphate, aluminium silicate, talc, and calcium carbonate.
In an embodiment of the present disclosure, the second levelling additive is at least one selected from the group consisting of polymethylalkylsiloxane, polyacrylate (silicon and fluorine free), and polyether (silicon and alkylphenol ethoxylates free).
In an embodiment of the present disclosure, the acrylic resin is at least one selected from the group consisting of butyl methyl acrylate (BMA), butyl methacrylate, methyl methacrylate (MMA), isobutyl methyl methacrylate (IBMA), methyl methacrylate (MMA)/isobutyl methyl methacrylate (IBMA) copolymer, thermoplastic methacrylate, and acrylic-polyurethane hybrid resin system.
In an embodiment of the present disclosure, the overprint varnish is at least one selected from the group consisting of acrylic varnish, polyurethane varnish, polyester-based varnish and polyurethane polyester hybrid varnish.
In an embodiment of the present disclosure, the overprint varnish comprises an isocyanate-based hardener in an amount in the range of 10 mass% to 15 mass%, with respect to the total mass of the overprint varnish.
In an embodiment of the present disclosure, a solid content in the first ink is in the range of 20 mass% to 55 mass%.
In an embodiment of the present disclosure, a solid content in the second ink is in the range of 10 % to 45 %.
In an embodiment of the present disclosure, a solid content in the overprint varnish is in the range of 45 % to 60%.
In an embodiment of the present disclosure, the peelable varnish is a PVC-free peelable varnish selected from acrylic polyester varnish and polyurethane-based varnish.
In an embodiment of the present disclosure, the temporary peelable varnish comprises butyl acetate as a solvent.
In another aspect, the present disclosure relates to a water slide decal comprising:
i. a water slide paper;
ii. a water-soluble adhesive layer coated over the water slide paper;
iii. a PVC-free ink system comprising a first ink and a second ink, coated on the water soluble adhesive layer; and
iv. a PVC-free peelable varnish coated on top of the PVC- free ink system,
wherein the varnish facilitates transfer of the ink system onto a target substrate upon application of water.
In an embodiment of the present disclosure, the decal is applied to the substrate selected from the group consisting of a metal surface, an acrylonitrile butadiene styrene (ABS) surface, a plastic surface, a wood surface, a glass surface, and a ceramic surface.
In an embodiment of the present disclosure, the water slide decal is characterized by having a thickness in the range of 45 µm to 60 µm.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a flow chart of a process for preparing a water-slide decal in accordance with the present disclosure.
DETAILED DESCRIPTION
The present disclosure relates to the field of graphics and decals. Particularly, the present disclosure relates to a process for the preparation of water slide decals and water slide decals obtained therefrom.
Embodiments of the present disclosure will now be described with reference to the accompanying drawings.
Embodiments of the present disclosure will now be described herein. Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used in the present disclosure is only for the purpose of explaining a particular embodiment, and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure, as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein, do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Conventional vinyl-based decals (PVC decals) have a variety of disadvantages, wherein the use of PVC involves the release of toxic chlorine-based chemicals, resulting in highly toxic and carcinogenic by-products such as dioxins, polychlorinated biphenyls (PCBs) and the like. The decals may peel or lift over time, particularly in extreme weather, and they may not adhere well to uneven or rough surfaces. Further, the prolonged exposure to the sun may cause the material to fade, shatter, or shrink. They can be difficult to apply to curved or irregular surfaces, and removing them may result in a sticky residue or surface damage. Although water-slide decals are environmentally friendly, traditional methods for producing them often involve the use of solvents and water-activated adhesives that can be inconsistent in adhesion.
The present disclosure provides a process for the preparation of a water-slide decal and water-slide decal obtained therefrom.
In an aspect, the present disclosure relates to a process for the preparation of water slide decals.
The process comprises the steps of coating a water slide paper having a predetermined weight by an adhesive layer of a predetermined thickness to obtain a coated water slide paper. A first ink is screen printed on the coated water slide paper with a first predetermined mesh size, followed by drying under infrared radiation at a predetermined temperature for a first predetermined time period to obtain a first printed substrate. A predetermined pattern is screen printed using a second ink on the first printed substrate with a second predetermined mesh size, followed by drying under infrared radiation at the predetermined temperature for the first predetermined time period to obtain a second printed substrate. An overprint varnish is screen printed over the second printed substrate with a third predetermined mesh size using screen printing techniques, followed by drying under infrared radiation at the predetermined temperature for a second predetermined time period to obtain a varnished substrate. A temporary peelable varnish is screen printed on the varnished substrate with a fourth predetermined mesh size, followed by drying a temperature in the range of 20 °C to 40 °C for a time period in the range of 12 hours to 30 hours to obtain the water slide decal.
The process is described in detail below.
In a first step, a water slide paper having a predetermined weight is coated by an adhesive layer of a predetermined thickness to obtain a coated water slide paper.
In an embodiment of the present disclosure, the water slide paper is selected from glucose and dextrose-based water slide paper. In an exemplary embodiment of the present disclosure, the water-slide paper is a glucose-based water slide paper.
In an embodiment of the present disclosure, the water slide paper comprises a long chain of glucose molecules.
In an embodiment of the present disclosure, the predetermined weight of the water slide paper is in the range of 165 gsm (grams per square meter) to 175 gsm. In an exemplary embodiment of the present disclosure, the predetermined weight of the water slide paper is 170 gsm.
In an embodiment of the present disclosure, the adhesive is a water-soluble glucose-based adhesive selected from a-D-glucose based adhesive and ß-D-glucose based adhesive. In an exemplary embodiment of the present disclosure, the adhesive is a-D-glucose based adhesive.
In an embodiment of the present disclosure, the predetermined thickness of the adhesive layer is in the range of 4 µm to 18 µm. In an exemplary embodiment of the present disclosure, the predetermined thickness of the adhesive layer is 9 µm to 10 µm.
In an embodiment of the present disclosure, the coating of the adhesive layer is carried out by screen printing.
In a second step, a first ink is screen printed on the coated water slide paper with a first predetermined mesh size, followed by drying under infra-red radiation at a predetermined temperature for a first predetermined time period to obtain a first printed substrate.
In an embodiment of the present disclosure, the first ink is a white ink at least one selected from the group consisting of a solvent-based ink, a solvent-based UV hybrid ink, a solvent-based LED hybrid ink, a water-based ink, a UV-water-based ink, a LED-water-based ink, a non-solvent UV-based ink and a non-solvent LED-based ink. In an exemplary embodiment, the first ink is a solvent based ink.
In an embodiment of the present disclosure, the first ink is at least one selected from high-density, glossy, satin and matt inks.
In an embodiment of the present disclosure, the first ink is a solvent based ink.
In an embodiment of the present disclosure, the first ink comprises:
i. a first pigment in an amount in the range of 20 mass% to 50 mass%;
ii. a first resin in an amount in the range of 10 mass% to 50 mass%;
iii. a first fluid medium in an amount in the range of 30 mass% to 70 mass%;
iv. a first plasticizer in an amount in the range of 1 mass% to 3 mass%;
v. a first extender in an amount in the range of 2 mass% to 7 mass%; and
vi. a first levelling additive in an amount in the range of 0.5 mass% to 5 mass%,
wherein the mass% of each component is with respect to the total mass of the first ink composition.
In an embodiment of the present disclosure, the first pigment is rutile titanium dioxide (TiO2).
In an exemplary embodiment, the first pigment is present in an amount of 36.47 mass% with respect to the total mass of the first ink composition.
In an embodiment of the present disclosure, the first resin is at least one selected from the group consisting of acrylic resin, aliphatic polyurethane resin, and urethane polyester copolymer.
In an embodiment of the present disclosure, the acrylic resin is at least one selected from the group consisting of butyl methyl acrylate (BmA), butyl methacrylate, methyl methacrylate (MMA), isobutyl methyl methacrylate (IBMA), methyl methacrylate (MMA)/ isobutyl methyl methacrylate (IBMA) copolymer, thermoplastic methacrylate and acrylic-polyurethane hybrid resin system.
In an exemplary embodiment, the first resin is a blend of butyl methyl acrylate and polyurethane resin.
In an exemplary embodiment, the first resin is present in an amount of 20 mass% with respect to the total mass of the first ink composition.
In an embodiment of the present disclosure, the first fluid medium is at least one selected from the group consisting of C9 aromatic solvents, 2-butoxy ethanol, cyclohexanone mixture, butyl carbitol, 1-methoxy-2-propanol, ethyl hexyl acetate, diethylene glycol diethyl ether (DEEG), gamma butyrolactone, propylene carbonate, dimethyl ester, dibasic ester, isopropyl acetoacetate, and derivatives of dibasic ester. In an exemplary embodiment, the first fluid medium is 2-butoxy ethanol (butyl cellosolve).
In an exemplary embodiment, the first fluid medium is present in an amount of 35.29 mass% with respect to the total mass of the first ink composition.
In an embodiment of the present disclosure, the first plasticizer is at least one selected from the group consisting of di-octyl maleate, ethyl hexyl adipate, and polylactic acid. In an exemplary embodiment, the first plasticizer is ethyl hexyl adipate.
In an exemplary embodiment, the first plasticizer is present in an amount of 1.18 mass% with respect to the total mass of the first ink composition.
In an embodiment of the present disclosure, the first extender is at least one selected from the group consisting of barium sulphate, aluminium silicate, talc, and calcium carbonate. In an exemplary embodiment, the first extender is aluminium silicate.
In an exemplary embodiment, the first extender is present in an amount of 5.88 mass% with respect to the total mass of the first ink composition.
In an embodiment of the present disclosure, the first levelling additive is silicon and silicon-free levelling additives selected from the group consisting of BYK777 (polymethylalkylsiloxane), BYK397 (polyacrylate (silicon and fluorine free)), and BYK3540 (polyether (silicon and alkylphenol ethoxylates free)). In an exemplary embodiment, the first levelling additive is BYK777 (polymethylalkylsiloxane).
In an exemplary embodiment, the first levelling additive is present in an amount of 1.17 mass% with respect to the total mass of the first ink composition.
In an exemplary embodiment, a solid content in the first ink is in the range of 20 mass% to 55 mass%. In an exemplary embodiment, the solid content in the first ink is 35 mass%.
In an embodiment of the present disclosure, the process for the preparation of the first ink composition comprises the following steps:
a) mixing predetermined amounts of at least one first resin, and at least one first fluid medium, under stirring at a speed in the range of 500 rpm to 1200 rpm for a time period in the range of 15 minutes to 45 minutes to obtain a first mixture;
b) adding a predetermined amount of at least one first pigment to the first mixture, followed by stirring at a speed in the range of 500 rpm to 1200 rpm for a time period in the range of 15 minutes to 45 minutes to obtain a second mixture;
c) subjecting the second mixture to pass through a triple roll mill to obtain a first homogeneous mixture having a particle size in the range of 0.1 micron to 5 microns; and
d) mixing a predetermined amount of at least one first levelling additive, a first extender, and a first plasticizer in the first homogenous mixture to obtain the first ink composition.
The present disclosure provides a screen printing ink composition and the process of its preparation of the first white ink, which is applied on water-slide paper. First screen printing ink of the present disclosure is based on a PVC-free resin system, which reduces the environmental impact throughout the life cycle of the product compared to the conventional PVC-based white ink.
In an embodiment of the present disclosure, the first predetermined mesh size is in the range of 70 TPI (Threads per inch) to 90 TPI (Threads per inch). In an exemplary embodiment of the present disclosure, the first predetermined mesh size is 77 TPI.
In an embodiment of the present disclosure, the predetermined temperature is in the range of 50 o C to 90 o C. In an exemplary embodiment of the present disclosure, the predetermined temperature is 60 °C.
In an embodiment of the present disclosure, the first predetermined time period is in the range of 1 minute to 10 minutes. In an exemplary embodiment of the present disclosure, the first predetermined time period is 7 minutes.
In a third step, a predetermined pattern is screen printed using a second ink on the first printed substrate with a second predetermined mesh size, followed by drying under infra-red radiation at the predetermined temperature for the first predetermined time period to obtain a second printed substrate.
In an embodiment of the present disclosure, the second ink is a color ink at least one selected from the group consisting of a solvent-based ink, a solvent-based UV hybrid ink, a solvent-based LED hybrid ink, a water-based ink, a UV-water-based ink, a LED-water-based ink, a non-solvent UV-based ink and a non-solvent LED-based ink. In an exemplary embodiment, the second ink is a solvent-based ink.
In an embodiment of the present disclosure, the second ink is at least one selected from high-density, glossy, satin and matt inks.
In an embodiment of the present disclosure, the second ink is a color ink for which blue wool rating (lightfastness) is in the range of 6 to 8.
In an embodiment of the present disclosure, the second ink is a solvent-based ink.
In an embodiment of the present disclosure, the second ink comprises:
i. a second pigment in an amount in the range of 5 mass% to 35 mass%;
ii. a second resin in an amount in the range of 10 mass% to 50 mass%;
iii. a second fluid medium in an amount in the range of 30 mass% to 70 mass%;
iv. a second plasticizer in an amount in the range of 1 mass% to 3 mass%;
v. a second extender in an amount in the range of 0.4 mass% to 2 mass%; and
vi. a second levelling additive in an amount in the range of 0.5 mass% to 5 mass%,
wherein the mass% of each component is with respect to the total mass of the second ink composition.
In an embodiment of the present disclosure, the second pigment is at least one selected from the group consisting of pyrazolone orange (PO34), naphthol red AS (PR146), 3-hydroxy-4-[(2-methyl-5-nitrophenyl)azo]-N-(2-methylphenyl)-2-naphthalenecarboxamide (pigment red 17 - PR17), phthalocyanine pigment (Blue 15:3), octanoic acid (HR-02-C9), copper phthalocyanine green (Green PG-7), 2,9-dimethylquinacridone (Red-122), carbazole dioxazine violet (Violet-23), carbon black pigments, vermillion red pigments, emerald green pigments, aluminium pigments, bronze pigments, vacuum metallized pigments, and encapsulated metallics pigments. In an exemplary embodiment, the pigment is vermillion red pigment.
In an exemplary embodiment, the second pigment is present in an amount of 21.18 mass% with respect to the total mass of the second ink composition.
In an embodiment of the present disclosure, the second resin is at least one selected from the group consisting of acrylic resin, aliphatic polyurethane resin, and urethane polyester copolymer.
In an embodiment of the present disclosure, the acrylic resin is at least one selected from the group consisting of butyl methyl acrylate (BmA), butyl methacrylate, methyl methacrylate (MMA), isobutyl methyl methacrylate (IBMA), methyl methacrylate (MMA)/ isobutyl methyl methacrylate (IBMA) copolymer, thermoplastic methacrylate and acrylic-polyurethane hybrid resin system.
In an exemplary embodiment, the second resin is a blend of butyl methyl acrylate and polyurethane resin.
In an exemplary embodiment, the second resin is present in an amount of 23.53 mass% with respect to the total mass of the second ink composition.
In an embodiment of the present disclosure, the second fluid medium is at least one selected from the group consisting of C9 aromatic solvents, 2-butoxy ethanol, cyclohexanone mixture, butyl carbitol, 1-methoxy-2-propanol, ethyl hexyl acetate, diethylene glycol diethyl ether (DEEG), gamma butyrolactone, propylene carbonate, dimethyl ester, di-basic ester, isopropyl acetoacetate, derivatives of dibasic ester. In an exemplary embodiment, the second fluid medium is 2-butoxy ethanol (butyl cellosolve).
In an exemplary embodiment, the second fluid medium is present in an amount of 51.76 mass% with respect to the total mass of the second ink composition.
In an embodiment of the present disclosure, the second plasticizer is at least one selected from the group consisting of di-octyl maleate, ethyl hexyl adipate, and polylactic acid. In an exemplary embodiment, the second plasticizer is ethyl hexyl adipate.
In an exemplary embodiment, the second plasticizer is present in an amount of 1.41 mass% with respect to the total mass of the second ink composition.
In an embodiment of the present disclosure, the second extender is at least one selected from the group consisting of barium sulphate, aluminium silicate, talc, and calcium carbonate. In an exemplary embodiment, the second extender is aluminium silicate.
In an exemplary embodiment, the second extender is present in an amount of 0.8 mass% with respect to the total mass of the second ink composition.
In an embodiment of the present disclosure, the second levelling additive is selected from the group consisting of polymethylalkylsiloxane, polyacrylate (silicon and fluorine free), and polyether (silicon and alkylphenol ethoxylates free). In an exemplary embodiment, the second levelling additive is polymethylalkylsiloxane.
In an embodiment of the present disclosure, the second levelling additive is selected from silicon and silicon-free levelling additives.
In an exemplary embodiment, the second levelling additive is present in an amount of 1.17 mass% with respect to the total mass of the second ink composition.
In an embodiment of the present disclosure, a solid content in the second ink is in the range of 10 % to 45 %. In an exemplary embodiment, the solid content in the second ink is 40 mass%.
In an embodiment of the present disclosure, the process for the preparation of the second ink composition comprises the following steps:
a) mixing predetermined amounts of at least one second resin, and at least one second fluid medium, under stirring at a speed in the range of 500 rpm to 1200 rpm for a time period in the range of 15 minutes to 45 minutes to obtain a third mixture;
b) adding a predetermined amount of at least one second pigment to the third mixture, followed by stirring at a speed in the range of 500 rpm to 1200 rpm for a time period in the range of 15 minutes to 45 minutes to obtain a fourth mixture;
c) subjecting the fourth mixture to pass through a triple roll mill to obtain a second homogeneous mixture having a particle size in the range of 0.1 micron to 5 microns; and
d) mixing a predetermined amount of at least one second levelling additive, a second extender, and a second plasticizer in the second homogenous mixture to obtain the second ink composition.
The present disclosure provides a second ink composition and the process of its preparation, and a second ink which is applied on the first white printed substrate. The second color screen printing ink of the present disclosure is based on PVC PVC-free resin system, which reduces the environmental impact throughout the life cycle of the product compared to the previous PVC-based color ink.
In an embodiment of the present disclosure, the second predetermined mesh size is in the range of 80 TPI (Threads per inch) to 110 TPI (Threads per inch). In an exemplary embodiment of the present disclosure, the second predetermined mesh size is 90 TPI.
In an embodiment of the present disclosure, the predetermined temperature is in the range of 50 oC to 90 oC. In an exemplary embodiment of the present disclosure, the predetermined temperature is 60 °C.
In an embodiment of the present disclosure, the first predetermined time period is in the range of 1 minute to 10 minutes. In an exemplary embodiment of the present disclosure, the first predetermined time period is 5 minutes.
In a fourth step, an overprint varnish is screen printed over the second printed substrate with a third predetermined mesh size, followed by drying under infrared radiation at the predetermined temperature for the second predetermined time period to obtain a varnished substrate.
In an embodiment of the present disclosure, the overprint varnish is selected from the group consisting of acrylic varnish, polyurethane varnish, polyester-based varnish, and polyurethane polyester hybrid varnish. In an exemplary embodiment of the present disclosure, the overprint varnish is acrylic-based varnish.
Following the colour application, an overprint varnish is applied to protect and enhance the decal. In an embodiment, the varnish is selected from the group consisting of acrylic, polyurethane, polyester-based, and polyurethane-polyester hybrid-based varnish.
In an embodiment of the present disclosure, the overprint varnish comprises an isocyanate-based hardener in an amount in the range of 10 mass% to 15 mass%, with respect to the total mass of the overprint varnish. In an exemplary embodiment, the overprint varnish comprises 10 mass% of isocyanate-based hardener.
In an exemplary embodiment, the acrylic-based varnish has a molecular weight in the range of 20,000 Mw to 1,50,000 Mw.
In an embodiment of the present disclosure, the solid content in the overprint varnish is in the range of 45 mass% to 60 mass%.
In an embodiment of the present disclosure, the third predetermined mesh size is in the range of 60 TPI (Threads per inch) to 90 TPI (Threads per inch). In an exemplary embodiment of the present disclosure, the third predetermined mesh size is 77 TPI.
In an embodiment of the present disclosure, the predetermined temperature is in the range of 50 oC to 90 oC. In an exemplary embodiment of the present disclosure, the predetermined temperature is 70 °C.
In an embodiment of the present disclosure, the second predetermined time period is in the range of 12 minutes to 40 minutes. In an exemplary embodiment of the present disclosure, the second predetermined time period is 30 minutes.
In a fifth step, a temporary peelable varnish is screen printed on the varnished substrate with a fourth predetermined mesh size, followed by drying a temperature in the range of 20 °C to 40 °C for a time period in the range of 18 hours to 30 hours to obtain the water slide decal.
In an embodiment of the present disclosure, the temporary peelable varnish is selected from the group consisting of acrylic polyester varnish and polyurethane-based varnish.
In an exemplary embodiment of the present disclosure, the temporary peelable varnish is a polyurethane-based varnish.
In an embodiment of the present disclosure, the temporary peelable varnish comprises butyl acetate as a solvent.
In an embodiment of the present disclosure, the peelable varnish is used as a temporary coating on the printed water slide paper. The peelable varnish provides an easy releasing property, which acts as a temporary protective film for the water slide decal of the present disclosure and is environmental friendly.
In an embodiment of the present disclosure, the fourth predetermined mesh size is in the range of 20 TPI (Threads per inch) to 30 TPI (Threads per inch). In an exemplary embodiment of the present disclosure, the fourth predetermined mesh size is 24 TPI.
In an embodiment of the present disclosure, the temperature for drying is 25 °C.
In an embodiment of the present disclosure, the time period for drying is 24 hours.
A water slide decal comprising:
i. a water slide paper;
ii. a water-soluble adhesive layer coated over the water slide paper;
iii. a PVC-free ink system comprising a first ink and a second ink, coated on the water soluble adhesive layer; and
iv. a PVC-free peelable varnish coated on top of the PVC- free ink system,
wherein the varnish facilitates transfer of the ink system onto a target substrate upon application of water.
In an embodiment of the present disclosure, the decal is applied to a substrate selected from the group consisting of a metal surface, an acrylonitrile butadiene styrene (ABS) surface, a plastic surface, a wood, a plastic surface, a glass, and a ceramic surface.
In yet another aspect, the present disclosure provides a process for obtaining a decal surface by transferring the water slide decal onto a surface. The process comprises the steps of treating the surface to obtain a treated surface. The water slide decal is wet for a time period in the range of 1 minute to 4 minutes to obtain a wet water slide decal. The water slide paper is removed from the wet water slide decal to obtain a film having an exposed side. The exposed side of the film is placed onto the treated surface, followed by applying manual pressure to the film on the treated surface such that the exposed part of the film is in contact with the treated surface to obtain a transferred decal. The temporary peelable varnish is removed from the transferred decal. The decal is varnished using a varnish selected from UV-based varnish and solvent-based varnish to obtain the decal surface.
The process is described in detail below.
In an embodiment of the present disclosure, the substrate is selected from the group consisting of metal and acrylonitrile butadiene styrene (ABS) surface, wood, glass, and ceramics. In an exemplary embodiment of the present disclosure, the surface is a metal surface.
In a first step, a surface of the substrate is treated to obtain a treated surface.
In an embodiment, the surface of the substrate is treated with a primer. In an embodiment of the present disclosure, the primer is at least one selected from the group consisting of polyurethane (PU) and thermal setting acrylic (TSA) lacquer. In an exemplary embodiment of the present disclosure, the primer is a mixture of polyurethane (PU) and thermal-setting acrylic (TSA) lacquer.
In an embodiment of the present disclosure, the primer is sprayed onto the surface to achieve a thickness between 22 µm to 30 µm.
After the primer has been applied on the surface and dried, the surface is coated with a layer of paint.
In an embodiment of the present disclosure, the paint is at least one selected from the group consisting of polyurethane (PU) and thermal setting acrylic (TSA) paint/lacquer. In an exemplary embodiment of the present disclosure, the paint is a mixture of polyurethane (PU) and thermal-setting acrylic (TSA) lacquer.
To maintain the thickness range of 22 microns to 30 microns on the surface, the paint is sprayed using a spray method.
The paint is dried at a temperature in the range of 20 °C to 40 °C for a time period in the range of 1 hour to 2 hours to obtain a treated surface.
In a second step, separately the water slide decal is wet for a time period in the range of 1 minute to 4 minutes to obtain a wet water slide decal.
This wetting allows the water slide decal to become pliable and ready for transfer.
In a third step, the water slide paper is removed from the wet water slide decal to obtain a film having an exposed side.
In a fourth step, the exposed side of the film is placed onto the treated surface, followed by applying manual pressure to the film on the treated surface such that the exposed part of the film is in contact with the treated surface to obtain a transferred decal.
In an embodiment of the present disclosure, to ensure that the decal adheres properly to the surface and to get rid of any extra water, the entire surface is dried at a temperature in the range of 60 oC to 80 oC for a time period in the range of 20 minutes to 30 minutes.
In a fifth step, the temporary peelable varnish is removed from the transferred decal.
In a sixth step, the decal is varnished using a varnish selected from UV-based varnish and solvent-based varnish to obtain the decal surface.
In an embodiment of the present disclosure, the varnish provides a protective coating that enhances the durability and longevity of the decal and painted surface.
Once the decal is securely in place and dried, the final step is to apply a protective lacquer/varnish over the entire surface.
In an embodiment of the present disclosure, the protective lacquer can be selected from TSA lacquer, a two-pack polyurethane-based lacquer, and an acrylic-based UV lacquer or any combination thereof. The final lacquer layer provides a protective coating that enhances the durability and longevity of the decal and painted surface.
In an embodiment of the present disclosure, the water slide decal is characterized by having a thickness in the range of 45 µm to 60 µm. In an exemplary embodiment, the water slide decal has a thickness of 50 µm.
Existing vinyl-based decals pose significant environmental concerns, primarily due to their polyvinyl chloride (PVC) content, which is non-biodegradable and releases toxic substances during disposal. Furthermore, traditional water-slide decals, although PVC-free, often suffer from inconsistent adhesion, poor durability, and smudging issues due to the limitations of their adhesive and ink compositions.
The present disclosure provides a method for the preparation of a water slide decal that provides a water slide decal that is biodegradable and versatile due to its ability to adhere to various substrates. The water slide decal provides multi-surface compatibility and ensures lightfastness and durability of decal ink.
The process for preparing the water slide decal is easy to scale up and can be used in the automotive sector, electronics, sports equipment and like.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment but are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
The present disclosure is further described in light of the following experiments which are set forth for illustration purpose only and not to be construed for limiting the scope of the disclosure. The following experiments are scalable to industrial/commercial processes.
EXPERIMENTAL DETAILS
Experiment 1: Preparation of PVC-free ink in accordance with the present disclosure
Step I: Preparation of the first ink
12 g of butyl methyl acrylate (first resin) and 5 g of polyurethane resin (first resin) were mixed in 30 g of butyl cellosolve/ 2-butoxy ethanol (first fluid medium) to obtain a first mixture. 31 g of rutile titanium dioxide (first pigment) was added to the first mixture under stirring for 15 minutes to obtain a second mixture. The second mixture was passed through a triple roll mill to obtain a homogeneous second mixture having a particle size of less than or equal to 5 microns. 1 g of polymethylalkylsiloxane (first levelling additive), 5 g of aluminium silicate (first extender), and 1 g of ethyl hexyl adipate were mixed in the first homogeneous mixture to obtain the first ink composition (solid content 35 mass%).
Step II: Preparation of the second ink
14 g of butyl methyl acrylate (second resin) and 6 g of polyurethane resin (second resin) were mixed in 44 g of butyl cellosolve/ 2-butoxy ethanol (second fluid medium) for 15 minutessto obtain a third mixture. 18 g of vermillion red (second pigment) was added to the third mixture under stirring for 15 minutes to obtain a fourth mixture. The mixture was passed through a triple roll mill to obtain a second homogeneous mixture having a particle size of less than or equal to 2 microns. 1 g of polymethylalkylsiloxane (second levelling additive), 0.80 g of aluminium silicate (second extender), and 1.2 g of ethyl hexyl adipate were mixed in the second homogeneous mixture to obtain the second ink composition (solid content of 40 mass%).
Experiment 2: Preparation of water slide decal in accordance with the present disclosure
Example 1
A glucose-based water slide paper (water slide paper) having a predetermined weight of 170 gsm was coated with a glucose-based gum (adhesive) to obtain a coated water slide paper (thickness of the gum on the water slide paper was 10 µm to 11 µm). The first ink obtained in step I of experiment 1 was screen printed on the coated water slide paper with a 77 TPI mesh size (first predetermined mesh size), followed by drying at under infra-red radiations at 60 °C (predetermined temperature) for 7 minutes (first predetermined time period) to obtain a first printed substrate. A predetermined design pattern was screen printed using the second ink obtained in step II of experiment 1, on the first printed substrate with mesh size of 90 TPI (second predetermined mesh size) followed by drying under infra-red radiation at 60 °C (predetermined temperature) for 5 minutes (first predetermined time period) to obtain a second printed substrate.
Further, an acrylic-polyester-polyurethane based polymer/copolymer varnish with 10% isocyanate (overprint varnish) having a molecular weight 5000 to 50000 Mn and a solid content of 45% to 60% was screen printed over the second printed substrate with a 77 TPI mesh size (third predetermined mesh size), followed by drying under infrared radiations at 70 °C (predetermined temperature) for 30 minutes (second predetermined time period) to obtain a varnished substrate. An acrylic based peelable varnish (temporary peelable varnish) was printed on the varnished substrate with a 24 TPI mesh size (fourth predetermined mesh size) followed by drying at 25 °C for 24 hours to obtain the water slide decal as illustrated in Figure 1.
Example 2
A glucose-based water slide paper (water slide paper) having a predetermined weight of 170 gsm was coated with an a-D-glucose-based gum (adhesive) to obtain a coated water slide paper (thickness of the gum on the water slide paper was 10 µm to 11 µm). White colour high-density satin durable ink (first ink) screen printed on the coated water slide paper with a 77 TPI mesh size (first predetermined mesh size), followed by drying at under infra-red radiations at 60 °C (predetermined temperature) for 7 minutes (first predetermined time period) to obtain a first printed substrate. A predetermined design pattern was screen printed using acrylic-polyurethane based polymer/copolymer ink (a second ink) on the first printed substrate with mesh size of 90 TPI (second predetermined mesh size) followed by drying under infra-red radiations at 60 °C (predetermined temperature) for 5 minutes (first predetermined time period) to obtain a second printed substrate.
Further, an acrylic-polyester-polyurethane based polymer/copolymer varnish with 10% isocyanate (overprint varnish) was screen printed over the second printed substrate with a 77 TPI mesh size (third predetermined mesh size), followed by drying under infrared radiations at 70 °C (predetermined temperature) for 30 minutes (second predetermined time period) to obtain a varnished substrate. An acrylic based peelable varnish (temporary peelable varnish) was printed on the varnished substrate with a 24 TPI mesh size (fourth predetermined mesh size) followed by drying at 25 °C for 24 hours to obtain the water slide decal.
Example 3
Example 3 was carried out in a manner similar to Example 1, except that in step 1 first predetermined mesh size was chosen as 90 TPI, the second predetermined mesh size was chosen as 100 TPI, and the third predetermined mesh size was chosen as 90 TPI.
Example 4
Example 4 was carried out in a manner similar to Example 1, except that in step 1 first predetermined mesh size was chosen as 100 TPI, the second predetermined mesh size was chosen as 100 TPI, and the third predetermined mesh size was chosen as 64 TPI.
Experiment 3: Obtaining a decal surface by transferring the water slide decal onto a surface in accordance with the present disclosure
A metal surface was treated with a polyurethane or TSA-based clear paint (primer) followed by drying to obtain a primer thickness of 22 µm to 30 µm. The primer layer is coated with a paint using a spray followed by drying at 25 °C for 1 hour (final thickness of 25 µm) to obtain a treated surface. The water slide decals obtained in Example 1 was wet for 2 minutes to obtain a wet water slide decal. The water slide paper was removed from the wet water slide decal to obtain a film having an exposed side. The exposed side of the film was placed onto the treated surface, followed by applying manual pressure to the film on the treated surface such that the exposed part of the film was in contact with the treated surface to obtain a transferred decal. The temporary peelable varnish was removed from the transferred decal. The decal was varnished using polyurethane or TSA-based matting or clear varnish to obtain the decal surface.
The water slide decals were obtained in a similar manner, except water slide decal obtained in Example 2, Example 3, and example 4 were used.
Experiment 4: Characteristics study of the water slide decal in accordance with the present disclosure
The decals obtained from Example 1, Example 2, Example 3, and Example 4 of the present disclosure were studied for various parameters/tests and were subjected to the following tests to ensure they meets all Original Equipment Manufacturer (OEM) standards.
Adhesion strength and durability tests
Peeling test
A peeling test was carried out as per ASTMD3359 on the water slide decals of Example 1, Example 2, and Example 3 of the present disclosure. It was observed that no peeling of ink was observed. From the results of the peeling test, it is clear that the water slide decal of the present disclosure exhibits superior 100/100 Adhesion.
Acid resistance test
The water slide decals of Example 1, Example 2, Example 3 and Example 4 were subjected to an acid resistance test by submerging the so obtained water slide decals of Example 1, Example 2, Example 3, and Example 4 in 0.1 N H2SO4 (sulphuric acid) for one hour. There were no abnormalities observed, such as peeling or lifting of the film observed in Examples 1, 2, 3, and 4 in accordance with the present disclosure, and the applied decal was completely free from decolourisation.
Alkali resistance test
The water slide decals of Example 1, Example 2, Example 3 and Example 4 were subjected to an alkali resistance test by submerging the so obtained water slide decals of Example 1, Example 2, Example 3, and Example 4 in 0.1 N NaOH (sodium hydroxide) for one hour. From the result of alkali resistance, it is clear that no abnormalities such as peeling or lifting of the film observed and applied decal completely free from decolourisation in Examples 1, 2, 3, and 4 in accordance with the present disclosure.
Oil resistance test
The water slide decals of Example 1, Example 2, and Example 3 were subjected to an oil resistance test by submerging the so obtained water slide decals of Example 1, Example 2, Example 3, and Example 4 in engine oil for two hours. Engine oil-10W30 for two hours. There were no abnormalities, such as peeling or lifting of the film observed, and the applied decal was completely free from decolourisation in Examples 1, 2, 3, and 4 in accordance with the present disclosure.
Petrol and Diesel resistance test
The water slide decals of Example 1, Example 2, and Example 3 were subjected to petrol and diesel resistance test by submerging the so obtained water slide decals of Example 1, Example 2, Example 3, and Example 4 in petrol and diesel for one hour each. No colour fading, peeling, cracks, softened adhesive, and blistering were observed in Examples 1, 2, 3, and 4 in accordance with the present disclosure.
Weatherometer test
The water slide decals of Example 1, Example 2, Example 3 and Example 4 were subjected to a weatherometer test by exposing the decals of each of the examples in a weatherometer for 1000 to 1500 hours to simulate long-term weathering effects. From the results of the weatherometer test, it is clear that water slide decal of the present disclosure has no influence of weather on color change or cracking of the film, no blister, peeling or cracks on the surface in Examples 1, 2, 3, and 4 in accordance with the present disclosure.
Furthermore, the ink system employed in the water slide decal of the present disclosure is completely free from polyvinyl chloride (PVC) and other halogenated compounds, which are traditionally used in conventional decal formulations. PVC and related substances are known to pose significant environmental and health concerns due to their non-biodegradable nature and the release of toxic by-products during degradation or incineration. By eliminating PVC from the ink composition, the present disclosure offers a greener and more sustainable alternative that is safer for both the end-user and the environment.
The PVC-free nature of the decal of the present disclosure also facilitates easier disposal and recycling, while maintaining superior performance in terms of adhesion strength, durability, resistance to chemicals (acid, alkali, oil, fuel), and weatherability, as demonstrated in the various tests detailed herein. Thus, the present disclosure provides a high-performance water slide decal solution without compromising environmental safety.
TECHNICAL ADVANCEMENT
The present disclosure described hereinabove has several technical advantages including, but not limited to, the realization of a method for preparing a water-slide decal that:
• is environment-friendly and does not use harmful chemicals;
• provides biodegradability as it uses biodegradable paper, PVC-free ink, water-soluble adhesive, and renewable, biodegradable protective film;
• provides versatility due to the water-slide decal's ability to adhere to various substrates, including curved and irregular surfaces, expanding their applicability for complex designs and surfaces where vinyl decals may struggle to adhere effectively; and
• provides water slide decal as it seamlessly blends into the surface they are applied to, providing a more polished and integrated look compared to vinyl decals, which can sometimes appear more like stickers, and
? a water slide decal, that
• is compatible with a wide variety of ink and varnish systems, enabling versatile decal applications;
• ensures lightfastness and durability of the decal ink;
• is cost-effective;
• minimizes waste during the decal application process; and
• provides multi-surface compatibility.
Throughout this specification the word “comprises”, or variations such as “comprises” or “comprising, will be understood to imply the inclusion of a stated element, integer or step,” or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the invention to achieve one or more of the desired objects or results. While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only and are not intended to limit the scope of the inventions. Variations or modifications to the formulation of this invention, within the scope of the invention, may occur to those skilled in the art upon reviewing the disclosure herein. Such variations or modifications are well within the spirit of this invention.
The numerical values given for various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the invention unless there is a statement in the specification to the contrary.
While considerable emphasis has been placed herein on the specific features of the preferred embodiment, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiment without departing from the principles of the disclosure. These and other changes in the preferred embodiment of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.
,CLAIMS:WE CLAIM:
1. A process for the preparation of a water-slide decal, said process comprising the following steps:
a. coating a water slide paper having a predetermined weight by an adhesive layer of a predetermined thickness to obtain a coated water slide paper;
b. screen printing a first ink on said coated water slide paper with a first predetermined mesh size, followed by drying under infrared radiation at a predetermined temperature for a first predetermined time period to obtain a first printed substrate;
c. screen printing a predetermined pattern using a second ink on said first printed substrate with a second predetermined mesh size, followed by drying under infrared radiation at said predetermined temperature for said first predetermined time period to obtain a second printed substrate;
d. screen printing an overprint varnish over said second printed substrate with a third predetermined mesh size, followed by drying under infrared radiation at said predetermined temperature for a second predetermined time period to obtain a varnished substrate; and
e. screen printing a temporary peelable varnish on said varnished substrate with a fourth predetermined mesh size, followed by drying at a temperature in the range of 20 °C to 40 °C for a time period in the range of 12 hours to 30 hours to obtain said water slide decal.
2. The process as claimed in claim 1, wherein
• said water slide paper is selected from glucose based water slide paper and dextrose-based water slide paper;
• said predetermined weight of said paper is in the range of 165 gsm to 175 gsm;
• said adhesive is a water-soluble glucose-based adhesive selected from a-D-glucose based adhesive and ß-D-glucose based adhesive; and
• said predetermined thickness of said adhesive layer is in the range of 4 µm to 18 µm.
3. The process as claimed in claim 1, wherein
• said first predetermined mesh size is in the range of 70 TPI to 90 TPI;
• said second predetermined mesh size is in the range of 80 TPI to 110 TPI;
• said third predetermined mesh size is in the range of 60 TPI to 90 TPI; and
• said fourth predetermined mesh size is in the range of 20 TPI to 30 TPI.
4. The process as claimed in claim 1, wherein said predetermined temperature is in the range of 50 °C to 90 °C.
5. The process as claimed in claim 1, wherein
• said first predetermined time period is in the range of 1 minute to 10 minutes; and
• said second predetermined time period is in the range of 12 minutes to 40 minutes.
6. The process as claimed in claim 1, wherein said first ink is a white ink and said second ink is a color ink and are at least one selected from the group consisting of a solvent-based ink, a solvent-based UV hybrid ink, a solvent-based LED hybrid ink, a water-based ink, a UV-water-based ink, a LED-water-based ink, a non-solvent UV-based ink and a non-solvent LED-based ink.
7. The process as claimed in claim 6, wherein said first ink comprises:
i. a first pigment in an amount in the range of 20 mass% to 50 mass%;
ii. a first resin in an amount in the range of 10 mass% to 50 mass%;
iii. a first fluid medium in an amount in the range of 30 mass% to 70 mass%;
iv. a first plasticizer in an amount in the range of 1 mass% to 3 mass%;
v. a first extender in an amount in the range of 2 mass% to 7 mass%; and
vi. a first levelling additive in an amount in the range of 0.5 mass% to 5 mass%,
wherein the mass% of each component is with respect to the total mass of said first ink composition.
8. The process as claimed in claim 6, wherein said second ink comprises:
i. a second pigment in an amount in the range of 5 mass% to 35 mass%;
ii. a second resin in an amount in the range of 10 mass% to 50 mass%;
iii. a second fluid medium in an amount in the range of 30 mass% to 70 mass%;
iv. a second plasticizer in an amount in the range of 1 mass% to 3 mass%;
v. a second extender in an amount in the range of 0.4 mass% to 2 mass%; and
vi. a second levelling additive in an amount in the range of 0.5 mass% to 5 mass%,
wherein the mass% of each component is with respect to the total mass of said second ink composition.
9. The process as claimed in claim 7, wherein
• said first pigment is rutile titanium dioxide (TiO2);
• said first resin is at least one selected from the group consisting of acrylic resin, aliphatic polyurethane resin, and urethane polyester copolymer;
• said first fluid medium is at least one selected from the group consisting of C9 aromatic solvents, 2-butoxy ethanol, cyclohexanone mixture, butyl carbitol, 1-methoxy-2-propanol, ethyl hexyl acetate, diethylene glycol diethyl ether (DEEG), gamma butyrolactone, propylene carbonate, dimethyl ester, dibasic ester, isopropyl acetoacetate, and derivatives of dibasic ester;
• said first plasticizer is at least one selected from the group consisting of di-octyl maleate, ethyl hexyl adipate, and polylactic acid;
• said first extender is at least one selected from the group consisting of barium sulphate, aluminium silicate, talc, and calcium carbonate; and
• said first levelling additive is at least one selected from the group consisting of polymethylalkylsiloxane, polyacrylate (silicon and fluorine free), and polyether (silicon and alkylphenol ethoxylates free).
10. The process as claimed in claim 8, wherein
• said second pigment is at least one selected from the group consisting of pyrazolone orange, naphthol red AS, 3-hydroxy-4-[(2-methyl-5-nitrophenyl)azo]-N-(2-methylphenyl)-2-naphthalenecarboxamide, phthalocyanine pigment, octanoic acid, copper phthalocyanine green, 2,9-dimethylquinacridone, carbazole dioxazine violet, carbon black, vermillion red, emerald green, aluminium pigments, bronze pigments, vacuum metallized pigments, and encapsulated metallic pigments;
• said second resin is at least one selected from the group consisting of acrylic resin, aliphatic polyurethane resin, and urethane polyester copolymer;
• said second fluid medium is at least one selected from the group consisting of C9 aromatic solvents, 2-butoxy ethanol, cyclohexanone mixture, butyl carbitol, 1-methoxy-2-propanol, ethyl hexyl acetate, diethylene glycol diethyl ether (DEEG), gamma butyrolactone, propylene carbonate, dimethyl ester, di-basic ester, isopropyl acetoacetate, and derivatives of dibasic ester;
• said second plasticizer is at least one selected from the group consisting of di-octyl maleate, ethyl hexyl adipate, and polylactic acid;
• said second extender is at least one selected from the group consisting of barium sulphate, aluminium silicate, talc, and calcium carbonate; and
• said second levelling additive is at least one selected from the group consisting of polymethylalkylsiloxane, polyacrylate (silicon and fluorine free), and polyether (silicon and alkylphenol ethoxylates free).
11. The process as claimed in claims 9 and 10, wherein said acrylic resin is at least one selected from the group consisting of butyl methyl acrylate (BMA), butyl methacrylate, methyl methacrylate (MMA), isobutyl methyl methacrylate (IBMA), methyl methacrylate (MMA)/isobutyl methyl methacrylate (IBMA) copolymer, thermoplastic methacrylate, and acrylic-polyurethane hybrid resin system.
12. The process as claimed in claim 1, wherein said overprint varnish is at least one selected from the group consisting of acrylic varnish, polyurethane varnish, polyester-based varnish and polyurethane polyester hybrid varnish.
13. The process as claimed in claim 1, wherein said overprint varnish comprises an isocyanate-based hardener in an amount in the range of 10 mass% to 15 mass%, with respect to the total mass of said overprint varnish.
14. The process as claimed in claim 1, wherein a solid content in said first ink is in the range of 20 mass% to 55 mass%.
15. The process as claimed in claim 1, wherein a solid content in said second ink is in the range of 10 % to 45 %.
16. The process as claimed in claim 1, wherein a solid content in said overprint varnish is in the range of 45 % to 60%.
17. The process as claimed in claim 1, wherein said peelable varnish is a PVC-free peelable varnish selected from acrylic polyester varnish and polyurethane-based varnish.
18. The process as claimed in claim 1, wherein said temporary peelable varnish comprises butyl acetate as a solvent.
19. A water slide decal comprising:
i. a water slide paper;
ii. a water-soluble adhesive layer coated over said water slide paper;
iii. a PVC-free ink system comprising a first ink and a second ink, coated on said water soluble adhesive layer; and
iv. a PVC-free peelable varnish coated on top of said PVC- free ink system,
wherein said varnish facilitates transfer of the ink system onto a target substrate upon application of water.
20. The water slide decal as claimed in claim 19, wherein said decal is applied to said substrate selected from the group consisting of a metal surface, an acrylonitrile butadiene styrene (ABS) surface, a plastic surface, a wood surface, a glass surface, and a ceramic surface.
21. The water slide decal as claimed in claim 20, wherein said water slide decal is characterized by having a thickness in the range of 45 µm to 60 µm.

Dated this 28th day of June 2025

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
OF R. K. DEWAN & CO.
AUTHORIZED AGENT OF APPLICANT

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI