Decorative Sheet Printing With High-Viscosity Ink for Bleeding Control
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Solution Overview
Problem
Existing methods for manufacturing decorative panels face issues with ink bleeding and nozzle clogging due to low viscosity inks, leading to reduced printing quality and increased material usage, particularly in digital printing processes.
Innovation Solution
Employing high viscosity pigmented inks (above 30 mPas) with reduced vehicle content and increased pigment content, along with the use of digital inkjet printers, to minimize ink spreading and enhance printing quality, while eliminating the need for ink receiver layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If low viscosity pigmented ink is used for digital printing, then the ink can be easily applied and spread, but the ink bleeds during resin impregnation and causes nozzle clogging
Solution Approach 1:
The patent changes the viscosity parameter of the pigmented ink from low (conventional) to high (above 30 mPas). This parameter change prevents ink bleeding during resin impregnation and eliminates nozzle clogging, while still allowing the ink to be applied effectively through digital printing processes.
2Manufacturing precision
If ink receiver layers are applied to prevent ink bleeding, then ink spread is controlled, but lamination issues occur and printer nozzles clog
Solution Approach 1:
The patent removes the ink receiver layer from the decorative sheet structure. By using high viscosity pigmented ink directly on the decorative paper, the need for an intermediate ink receiver layer is eliminated, thereby preventing both lamination defects and nozzle clogging associated with these layers.
3Adaptability or versatility
If direct digital printing is applied to thermoplastic foil, then printing flexibility is improved, but ink droplets spread laterally reducing resolution
Solution Approach 1:
The patent applies high viscosity pigmented ink (above 30 mPas) for direct printing on thermoplastic foils. The high viscosity parameter prevents lateral spreading of ink droplets on the non-porous thermoplastic surface, maintaining high printing resolution while preserving the versatility of direct digital printing methods.
4Manufacturing precision
If more ink receiver layers are applied to reduce ink bleeding, then ink containment improves, but material usage increases and processing complexity increases
Solution Approach 1:
The patent eliminates the need for ink receiver layers by using high viscosity pigmented ink. This extraction of the unnecessary component reduces material usage and simplifies the overall structure while maintaining effective ink bleeding control through the inherent properties of the high viscosity ink.
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
Improves printing resolution, reduces material usage, and minimizes energy consumption by limiting ink penetration and drying time, thereby enhancing the manufacturing process efficiency and quality of decorative panels.
Implementation Method 1
the pigmented ink has a viscosity above 30 mPas, preferably above 40 mPas
Implementation Method 2
When printing onto printable sheets which are adapted to absorb the vehicle of the ink, for example a porous printable sheet like a paper sheet
Data Source
Figure 1~4
Figure 5
AI summary
Method for manufacturing a decorative sheet (1) for making decorative panels (11), wherein the method at least comprises the following steps: - the step of providing a sheet (2), preferably a paper layer or a thermoplastic foil; - the step of applying a printed motif (4) to the sheet (2) by means of digital printing; wherein the printed motif (4) is applied using a pigmented ink; wherein the pigmented ink has a viscosity above 30 mPa.s, preferably above 40 mPa.s. The invention also relates to the decorative sheets (1) obtained by the method, as well to a method for manufacturing a decorative panel (11) comprising said decorative sheet (1).