Digital Ceramic Coating via Dry Pigment and Liquid Binder
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Solution Overview
Problem
Conventional digital printing methods for ceramics and glass surfaces face issues with abrasion and plugging due to the use of inorganic pigments, leading to unreliable and costly operations.
Innovation Solution
The method involves conveying solid pigment particles dry onto the surface, using a system with an electrostatic charger and a printer that applies a liquid binder, followed by removal of non-fixed particles, eliminating the need for inkjet nozzle cleaning and reducing maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inorganic pigment is applied in conventional liquid jet printing, then decorative coating is achieved, but abrasion and plugging occur leading to unreliable operation
Solution Approach 1:
The patent separates the pigment application and binding processes into distinct stages: first conveying dry pigment particles onto the surface, then applying liquid binder separately. This segmentation prevents pigment-laden liquid from contacting and plugging the print head nozzles, eliminating the harmful effects while maintaining decorative coating quality.
Solution Approach 2:
The patent introduces a dry pigment layer as an intermediary between the print head and the final coated surface. By conveying pigment particles dry onto the surface first, the system creates a mediator layer that receives the liquid binder without requiring the binder to carry abrasive pigment through the delicate inkjet nozzles, thus preventing plugging and abrasion.
2Manufacturing precision
If liquid paint containing inorganic pigment is used, then decorative coating is achieved, but maintenance costs increase due to nozzle cleaning
Solution Approach 1:
The patent extracts the pigment material from the liquid paint formulation and conveys it as separate dry particles onto the surface before binder application. This extraction eliminates the need for cleaning pigment residue from nozzles, significantly reducing maintenance costs while preserving the ability to produce high-quality decorative coatings with inorganic pigments.
Solution Approach 2:
The patent treats the dry pigment layer as a temporary, disposable intermediate that serves its purpose of receiving binder without requiring long-term durability during the printing process. This approach allows using simple, low-maintenance pigment application followed by binder curing, reducing overall system complexity and maintenance requirements compared to durable liquid paint systems.
3Strength
If binder material is applied in solution form, then pigment adhesion is achieved, but drying-in and deposition processes occur
Solution Approach 1:
The patent performs preliminary action by conveying dry pigment particles onto the surface and forming a pigment layer before applying the liquid binder. This sequence ensures that when the binder is applied, there is already a prepared pigment layer to adhere to, achieving strong adhesion without the binder needing to carry pigment through the nozzle system, thereby preventing drying-in and deposition issues.
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 ensures reliable, cost-effective digital printing by preventing pigment-related issues like abrasion and plugging, extending print head life and maintaining high-quality results without modifying existing ceramic technology formulas.
Implementation Method 1
conveying solid pigment particles is carried out in a dry state
Implementation Method 2
a binder material is applied to the surface, and then dry pigment is applied to the binder material, and sticks to it
Data Source
Figure 1
Figure 2~3
AI summary
Method for producing a digitally printed decorative coating on a solid surface, comprising the steps of: applying solid pigment dye (2) to the surface (1 ) and treating the coating such that the treatment results in the setting/hardening of the coating, where at first the dry surface (1 ) is evenly coated applying solid pigment dye (2) at least over the surface portion where the coating is to be applied, in a subsequent printing operation liquid is applied to the surface (1 ) coated with dry pigment dye (2), thereby temporarily fixing the solid pigment dye (2) to the printed-on surface portions, and before performing the treatment resulting in the setting/hardening of the coating, removing the non-fixed portion of the solid pigment dye (2) from the surface (1 ).