Digital Binder and Powder Print for Wear-Resistant Panels
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Solution Overview
Problem
Conventional digital printing methods for decorative surfaces on building panels, such as floors, face challenges with high ink costs, nozzle clogging, and the need for protective layers that are costly and not completely transparent, limiting the flexibility and wear resistance of the printed designs.
Innovation Solution
A two-step process involving the separate application of a liquid binder and dry colourants, where coloured particles are bonded to the surface with a digitally formed pattern, and non-bonded particles are removed, followed by pressing under increased temperature to create a hard, wear-resistant layer, using a cost-efficient water-based binder and pigment-coated wood fibres or mineral particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional digital printing methods use pigment-based inks, then colour quality is improved, but ink cost increases and nozzle clogging occurs
Solution Approach 1:
The printing process is divided into two separate steps: first applying a liquid binder without pigments, then applying dry pigment powder separately. This segmentation allows the binder to be applied without clogging nozzles, while the pigment is applied as a dry powder that does not cause clogging, resolving the contradiction between colour quality and nozzle reliability.
Solution Approach 2:
A liquid binder serves as an intermediary substance that is applied first to the substrate. This binder creates a receptive surface for the subsequent dry pigment powder application, allowing the pigment to adhere without requiring the pigment to be mixed in a liquid carrier that could clog nozzles.
2Manufacturing precision
If conventional digital printing uses expensive pigment-based inks, then print quality is improved, but production cost increases
Solution Approach 1:
The liquid binder used in the first step is a simple, inexpensive substance that does not require expensive pigments. By separating the binder application from the pigment application, the system uses cheap binder material while achieving high print quality through the subsequent dry pigment powder application, significantly reducing overall material costs.
Solution Approach 2:
The invention changes the physical state and form of the pigment from a liquid ink suspension to a dry powder form. This parameter change allows the pigment to be applied as a fine powder that can be precisely deposited, maintaining high print quality while using less expensive pigment materials and reducing overall ink consumption.
3Device complexity
If conventional printing applies ink directly to the surface, then the process is simplified, but wear resistance deteriorates
Solution Approach 1:
The liquid binder is applied as a preliminary layer before the dry pigment powder is applied. This preliminary binder layer creates a strong adhesive base that enhances the wear resistance of the final printed design. The binder penetrates and bonds with the substrate, providing a durable foundation for the pigment particles.
Solution Approach 2:
The final printed design consists of a composite structure with the liquid binder forming a binding matrix and dry pigment powder particles embedded within it. This composite material structure provides superior wear resistance compared to conventional liquid inks, as the dry pigment particles are mechanically interlocked and chemically bonded within the binder matrix.
4Strength
If conventional printing uses protective layers to enhance wear resistance, then durability is improved, but transparency and cost deteriorate
Solution Approach 1:
The invention extracts and eliminates the need for separate protective layers by integrating the wear-resistant function directly into the printing process itself. The liquid binder and dry pigment powder combination creates an inherently durable printed design that does not require additional protective coatings, reducing both material costs and production complexity.
Solution Approach 2:
The liquid binder serves multiple functions simultaneously: it acts as an adhesive to bond the pigment particles, provides wear resistance to protect the printed design, and creates a durable foundation for the pigment. This multi-functionality eliminates the need for separate protective layers, reducing overall material costs while maintaining or improving durability.
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 method reduces ink costs, avoids nozzle clogging, and achieves high-quality, wear-resistant digital prints with improved productivity, allowing for realistic wood and stone designs without the need for expensive inks or protective layers.
Implementation Method 1
a liquid binder and dry colourants are applied separately and bonded together
Implementation Method 2
The bonded coloured particles and the panel surface are pressed together and an increased bonding is obtained. The pressing is made under increased temperature such that the coloured particles and the surface are cured to a hard wear resistant layer.
Data Source
Figure 1a~1e
Figure 2a~2e
Figure 3a~3d
AI summary
The disclosure relates to an equipment (40) to provide a digital print (P) on a panel (1) comprising a surface (2). The equipment comprises a digital drop application head (30') adapted to apply liquid blank ink (11) on the surface and a dry ink application station (27) adapted to apply dry ink (15) comprising dry colourants on the liquid blank ink, wherein the liquid blank ink is adapted to bond a part of the colourants to the surface. The equipment further comprises a dry ink removal station (28) adapted to remove non-bonded colourants from the surface.