Teikoku Printing Inks Mfg. Co., Ltd.
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Q&A regarding Printing and Forming

  1. Binder


    2. Q01 What is a binder?
    Q02 Does ISX Ink need a binder?
    Q03 What is the difference between IMB 003 Binder and IMB 009 Binder?
    Q04 Why do two-pot inks need a Binder?

  2. Printing Process Concerns


    3. Q01 When over-printed with a black ink, we often have pinholes. How can we eliminate the pinholes?
    Q02 What are the standard drying conditions?
    Q03 Why is there "Primary" drying and "Final" drying?
    Q04 When we extended the primary drying time, pinholes and cracks resulted. How can we eliminate them?

  3. Injection Molding


    4. Q01 We found that sometimes when we peel off the print from the injected resin, ink remains on one side or sometimes on both sides. Why does this occur?
    Q02 The printed layer peeled away from the injected resin. What should we do?
    Q03 We have always had good adhesion, but suddenly peeling has occurred. What should we do?

  4. About FIM/IMD


    5. Q01 What is the meaning of FIM/IMD?
    Q02 What types of forming are available?
    Q03 Can you give some examples of which substrate films and molding resins can be combined when using the FIM/IMD method?
    Q04 From a recycling point of view, are there any actual cases of the same resin being used for both the substrate material and the molding resin?  If so, can you give some examples?
    Q05 What is the difference between Film Insert Molding and In Mold Decoration?  Do you use different inks for each?
    Q06 What is the largest size that you can use for the Insert Molding Method?
    Q07 Can you give some examples of the type of industry where a combination of ink and molding method is being used?  What would be the actual finished product?
    Q08 Do you have any restrictions when you use functional inks for molding inks?

  1. Binder


    2. Q01 What is a binder?
    A It is a binding layer, which enhances the binding between the injected resin and the inserted print matter, principally printed with 2 pots of curing ink.
    Q02 Does ISX Ink need a binder?
    A No it does not need a binder because ISX ink is a one-pot ink and has good adhesion to injected resin.
    Q03 What is the difference between IMB 003 Binder and IMB 009 Binder?
    A IMB 009 Binder is designed for Mirror Inks. When printed on MIB Ink, which is an overprint ink for Mirror Inks, it does not harm the mirror effect. Besides that it has better heat resistance. It is especially suitable to be used with PC resin. IMB 003 Binder is a general use binder and has good adhesion to a wide variety of resins such as PC, PC/ABS, ABS, PMMA and AS.
    Q04 Why do two-pot inks need a Binder?
    A When cured, a two-pot ink layer has a cross-linked structure and good heat resistance, in other words it is hard to melt at the high temperature of the injected melt resin. Therefore it has inferior adhesion to injected resin. The binder layer between the pattern printed layer and injected resin can strengthen the adhesion between them.

     

    Contact

    Teikoku Printing Inks Mfg. Co., Ltd.
    Tel +81-3-3800-9911
    Fax +81-3-3800-9919


  2. Printing Process Concerns


    3. Q01 When over-printed with a black ink, we often have pinholes. How can we eliminate the pinholes?
    A See the list below for causes of pinholes:
    1. The first layer is too thin (less than 5 microns)
    2. Too much dilution of the ink (more than 20%)
    3. Too much squeegee pressure
    4. Under layer is pale colored, such as a medium based color
    Any combination of these causes
    Q02 What are the standard drying conditions?
    A In multi-color printing, primary drying would be done after each color is printed. After the final color is printed, the final drying should be done according to the conditions listed in the catalog. If the color printed ink is a "two-pot" ink the final drying should be done after the printing of the Binder.
    Q03 Why there is "Primary" drying and "Final" drying?
    A Residual solvent at the time of injection may cause ink flow and insufficient adhesion. To prevent these malfunctions, residual solvent must be evaporated through a "Final" drying process.
    Q04 When we extended the primary drying time, pinholes and cracks resulted. How can we eliminate them?
    A With one-pot inks, if the primary drying time is too long, the solvent of second ink penetrates the first color layer and makes pinholes. With two-pot inks, if the primary drying time is too long, a curing process occurs. Thus when the second color is printed, the first color ink layer wrinkles and looks like cracks. The countermeasure in either case would be to shorten the primary drying time.

     

    Contact

    Teikoku Printing Inks Mfg. Co., Ltd.
    Operating Hours: 9:00 to 18:00 (except Sat, Sun & Holidays)
    Tel +81-3-3800-9911
    Fax +81-3-3800-9919

  3. Injection Molding


    4. Q01 We found that sometimes when we peel off the print from the injected resin, ink remains on one side or sometimes on both sides. Why does this occur?
    A In the case of ink remaining on the substrate, adhesion to the injected resin is poor. When ink remains on the injected resin, the adhesion to the substrate is poor. This is delamination. When ink remains on both sides, adhesion to substrate and injected resin are good, but the cohesion of the ink layer is poor. This is a cohesion failure.
    Q02 The printed layer peeled away from the injected resin. What should we do?
    A This may be due to a mismatch of ink, substrate and the resin. Please contact our representative.
    Q03 We have always had good adhesion, but suddenly peeling has occurred. What should we do?
    A Please check the following:
    1. Thickness of the ink layer.
      When ink layer is too thin adhesion might be decreased.
    2. Drying conditions of the ink layer.
      When drying time is not adequate, the strength of the ink layer becomes poor and cohesion failure may occur.
    3. Existence of additives such as defoamers.
      Some additives might decrease the adhesion.
    4. Temperature of the melted resin.
      If the temperature of the melted resin is too low, the binder and ink layer will not melt and this causes insufficient adhesion. Please set the temperature of melted resin and mold at a bit higher level.

     

    Contact

    Teikoku Printing Inks Mfg. Co., Ltd.
    Operating Hours: 9:00 to 18:00 (except Sat, Sun & Holidays)
    Tel +81-3-3800-9911
    Fax +81-3-3800-9919


  4. About FIM/IMD


    5. Q01 What is the meaning of FIM/IMD?
    A

    The abbreviations, FIM and IMD, stand for Film Insert Molding and In-Mold Decoration.  For these methods, the printed film is set into the mold and molded with molding resin as the finished product.  

    We recommend reading the following reports:

    No.133 Technical Report (Function): Add new color and function to plastic products.
    No.133 Technical Report (Technology): Technical information about utilizing FIM/IMD methods.
    Q02 What types of forming are there?
    A Typically, there are Vacuum Molding, Air-pressurized Molding, Press Molding, and High Pressure Molding.
    Q03 Using FIM/IMD method, can you give us some examples of substrate film and molding resin combinations?
    A PC, PET, and Acrylic substrate sheets are suitable.  Suitable resins are PC, PMMA, PC/ABS, AS, etc.  However, PP and Olefin are currently difficult to use because they do not have good adhesiveness to the substrate materials. 
    Q04 From a recycling point of view, are there any actual cases of the same resin being used for both the substrate material and the molding resin?  If so, can you give some examples?
    A ISX Ink for PC material sheet with PC resin is theoretically possible, however we do not have any actual cases of this as yet.
    Q05 What is the difference between Film Insert Molding and In Mold Decoration?  Do you use different inks for each?
    A For the FIM method, the printed surface will be placed between the substrate sheet and the resin. On the other hand, for IMD method, the printed surface will appear on top of the adhered layer of the substrate sheet and the resin.  The type ink will depend on the application and your requirements. 
    Q06 What is the largest size that you can use for the Insert Molding Method?
    A

    Theoretically, it depends on the capability of molding machine.  However, there is an elongation limit of the substrate sheet; it varies depending on the printing materials you are using.

    Q07 Can you give some examples of the type of industry where a combination of ink and molding method is being used?  What would be the actual finished product?
    A The main industries will be automobile interiors, amusements, and home appliances.  Their finished products are such items as speedometers, pinball game machines, water boilers, TVs and possibly as cover material in various other areas.
    Q08 Do you have any restrictions when you use functional inks for molding inks?
    A There are some limitations of color hue, glossiness, and other properties.  Sometimes, Teikoku Inks is unable to meet a customer’s requirements due to the design of the product.

     

    Contact

    Teikoku Printing Inks Mfg. Co., Ltd.
    Operating Hours: 9:00 to 18:00 (except Sat, Sun & Holidays)
    Tel +81-3-3800-9911
    Fax +81-3-3800-9919