Carpet Printing with Dual-Ink Overlay for Reproducible Color Depth
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Solution Overview
Problem
Current printing techniques for carpets, such as process and spot printing, face inefficiencies in producing consistent, reproducible, and cost-effective results due to low accuracy, high material costs, and the need for multiple layers and calibration, which limits productivity and ink penetration.
Innovation Solution
A method involving a textile printer with a printhead that applies two different inks with varying speeds and pH levels, allowing for simultaneous or sequential application of inks with surfactants and dispersants to achieve uniform mixing and fixation, thereby enhancing color reproduction and reducing the number of required inks and calibration steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If process printing is used to build up colors from primary colors, then color combinations can be produced, but efficiency is relatively low and multiple layers are required
Solution Approach 1:
The carpet surface is divided into multiple zones (first region, second region, third region) with different printing strategies applied to each zone, allowing efficient single-ink application in some areas while maintaining color versatility in others
Solution Approach 2:
Different printing approaches are applied to different regions: the first region receives a first ink, the second region receives both first and second inks, and the third region receives only a second ink, optimizing both efficiency and color capability for each local area
2Measurement precision
If spot printing is used with separate inks for each color, then color accuracy can be maintained, but reproducibility between batches is relatively low
Solution Approach 1:
The pH values of the inks are controlled within specific ranges (first ink: 3.0-6.0, second ink: 3.0-6.0) to ensure consistent chemical behavior and reproduction across different batches, while still achieving accurate color representation
Solution Approach 2:
The inks are pre-formulated with specific pH ranges and applied in a predetermined sequence (first ink then second ink), ensuring reproducible results across batches without requiring manual color mixing
3Manufacturing precision
If multiple layers of the same primary color are printed to obtain dark colors, then color depth can be achieved, but the number of printing steps increases
Solution Approach 1:
Multiple inks (first ink and second ink) are applied simultaneously or in sequence to the second region to achieve dark colors in a single printing pass, eliminating the need for multiple layers of the same color
4Ease of operation
If the printhead moves at constant speed during ink application, then printing simplicity is maintained, but ink penetration and mixing quality may be insufficient
Solution Approach 1:
The printhead speed is dynamically adjusted during printing: a first speed is used when applying the first ink, and a second speed (different from the first speed) is used when applying the second ink, optimizing ink penetration and mixing quality for each ink type
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
This approach allows for the efficient production of a wide range of colors with fewer inks, improved reproducibility, reduced material costs, and enhanced ink penetration, increasing productivity and quality while minimizing calibration requirements.
Implementation Method 1
applying a first ink in a first region and a second region; and applying a second ink in the second region
Implementation Method 2
the inks are applied with a textile printer that comprises a printhead
Implementation Method 3
the first ink and the second ink comprise one or more surfactants and/or dispersants, preferably as colour affine agents
Implementation Method 4
the first ink and/or the second ink is an acid ink, preferably with a pH of at most 6.0, preferably at most 5.0, preferably at most 4.0
Data Source
Figure 1~1(4)
Figure 2
Figure 3~5(d)
AI summary
A method is provided herein for applying ink on a carpet, the carpet comprising at least one first region and one second region, and the method comprising the following steps: - applying a first ink in the first region and in the second region; and - applying a second ink in the second region; wherein the first ink and the second ink are different, preferably wherein the first ink and the second ink each have a different hue.