Decor Printing Primer Control for Lower Ink and Drying Load

Solution Overview

Problem

Existing decorative printing processes are inefficient in terms of material costs, particularly for printing inks and primers, due to the need for uniform whiteness and consistent printing quality across different substrates, leading to high material and energy consumption.

Innovation Solution

Adapting the application quantity of primer based on predefined decor groups, adjusting color values in digital decor data sets, and optimizing the printing process to reduce primer and ink usage while maintaining print quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a uniform primer application rate is used across all substrates to ensure consistent whiteness and printing quality, then printing consistency is improved, but material costs and energy consumption increase

Engineering Contradiction:

Improveprinting consistencyVSAvoidprimer consumption

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The patent applies different primer application rates to different substrate groups based on their specific optical properties. Substrates are classified into groups with similar whiteness and color characteristics, and each group receives a tailored primer application rate. This local optimization approach maintains printing consistency within each group while reducing overall primer consumption compared to a uniform application rate across all substrates.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the primer application rate parameter based on substrate characteristics. By measuring substrate whiteness and color values and comparing them against reference values, the system dynamically adjusts the primer application rate to achieve target optical properties. This parameter adaptation allows optimal primer usage for each substrate type, reducing waste while maintaining print quality.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If high primer application rates are used to achieve uniform whiteness, then substrate color variations are compensated, but material costs and drying energy increase

Engineering Contradiction:

Improvewhiteness uniformityVSAvoiddrying energy

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent applies different primer application rates to different substrate groups based on their specific optical properties. Substrates are classified into groups with similar whiteness and color characteristics, and each group receives a tailored primer application rate. This local optimization approach maintains printing consistency within each group while reducing overall primer consumption compared to a uniform application rate across all substrates.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent applies primer in partially optimized quantities rather than excessive uniform amounts. By calculating the specific primer need for each substrate group based on measured deviations from reference values, the system applies only the necessary amount of primer required to achieve target whiteness and color, avoiding the excessive application that would increase drying energy consumption.

Inventive Principle:

Principle #16Partial or excessive action

3Quantity of substance

If substrate color variations are not compensated, then material and energy costs are reduced, but print quality deteriorates

Engineering Contradiction:

Improveprimer and ink consumptionVSAvoidprint quality

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent changes the primer application rate parameter based on substrate characteristics. By measuring substrate whiteness and color values and comparing them against reference values, the system dynamically adjusts the primer application rate to achieve target optical properties. This parameter adaptation allows optimal primer usage for each substrate type, reducing waste while maintaining print quality.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent implements a feedback mechanism where substrate optical properties are measured, compared against reference values, and used to adjust primer application rates. The system continuously monitors substrate characteristics and adapts the printing process parameters accordingly, ensuring print quality is maintained while optimizing material consumption through closed-loop control.

Inventive Principle:

Principle #23Feedback

Data Source

PatentEP4663423A1Method and device for efficiently printing a decoration on a substrate material

Publication Date: 2025.12.17 SWISS KRONO TEC AG

AI summary

The invention relates to a method and a device for efficiently printing a design onto a substrate. According to the invention, the amount of primer applied to a substrate is adapted to the design to be printed.