Continuous Digital Fabric Printing System to Reduce Processing Time
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Solution Overview
Problem
Conventional digital printing and finishing methods for fabrics are limited by independent sequential steps, leading to low productivity and long processing times, despite attempts to combine washing and drying steps continuously.
Innovation Solution
A continuous digital printing and finishing system where the fabric passes through a series of integrated stations, including unwinding, digital printing with piezoelectric ink-jet heads, immersion in a pH stabilization solution, steaming for ink fixation, washing, and drying, all performed in a sequential and synchronized manner to enhance speed and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional independent sequential steps are used for digital printing and finishing, then each step can be performed with standard equipment, but the overall processing time is long and productivity is limited
Solution Approach 1:
The patent combines multiple independent processing steps (printing, steaming, washing, drying) into a single continuous integrated system where the fabric passes through all stages sequentially without interruption. This merging eliminates the downtime and handling between separate operations, directly reducing total processing time while maintaining standard equipment functions.
Solution Approach 2:
The continuous printing system maintains uninterrupted fabric movement through all processing stages. The fabric is continuously fed through the printing zone, then immediately into the steaming chamber, followed by washing and drying sections, ensuring that the useful action of processing the fabric never stops. This continuity eliminates idle time and maximizes productivity.
2Loss of time
If washing and drying steps are performed continuously, then some processing time is reduced, but the overall processing time remains insufficiently reduced
Solution Approach 1:
The patent merges the washing and drying steps into a single continuous section where wet fabric from the steaming chamber is immediately conveyed through the washing zone and then directly into the drying section without interruption. This integration ensures that the fabric is processed through all stages continuously, maximizing the reduction of total processing time.
3Ease of manufacture
If multiple independent processing steps are used, then each step can be optimized separately, but the system complexity and manual intervention requirements increase
Solution Approach 1:
The continuous printing system is divided into distinct functional sections (printing zone, steaming chamber, washing section, drying section), each with its own optimized parameters and equipment. This segmentation allows each section to be independently designed and optimized for its specific function while being integrated into a continuous flow system, balancing flexibility with streamlined operation.
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 method significantly reduces processing times, increases productivity, minimizes manual intervention, and offers energy savings through reduced drying processes and evaporation times, while ensuring reliability and safety.
Implementation Method 1
transversely to the conveyor belt 5, there is a plurality of bars 6 provided with printing heads 7 which are controlled electronically and synchronized with the movement of the conveyor belt 5. More precisely, the printing heads 7 are of the piezoelectric ink-jet type
Implementation Method 2
a step of steaming the fabric 2 printed and impregnated with the aqueous solution 9 through a steaming chamber 12 in such a manner as to fix the ink to the fabric 2
Implementation Method 3
a step of steaming the fabric 2 printed and impregnated with the aqueous solution 9 through a steaming chamber 12
Data Source
Figure 1~4
Figure 2
Figure 3
AI summary
The present invention relates to a printing system and method (1a; 1b) for printing fabric comprising an input station configured for providing a fabric (2), a station, adapted for compensating the speeds and spreading the fabric (2), configured for positioning it on a conveyor belt (5), a digital printing station configured for digitally printing fabric (2) on the conveyor belt (5), the digital printing station comprising a plurality of bars placed transversely to the conveyor belt (5), the plurality of bars (6) provided with printing heads (7) which are controlled electronically and synchronized with the movement of the conveyor belt (5), a drying station configured for drying said fabric (2), an output station configured for collecting said fabric (2).