Digital Glass Ink Processing for Functional Film Dissolution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing digital inks for glass printing with functional films are ineffective in dissolving thin films due to contamination from metallic particles during grinding, which affects the ink's ability to apply the correct thickness and composition, and traditional methods like screen printing are cumbersome and wasteful.
Innovation Solution
A two-stage milling process using zirconia micro-bead mills and magnetic iron removers to reduce particle size to 3 microns, followed by thermal calcination, ensures the ink is free of contaminants and can accurately dissolve functional films on glass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional screen printing is used to apply ink on glass with functional films, then the ink can be applied, but the process requires screen changes for different designs and sizes, making it costly and time-consuming
Solution Approach 1:
The patent replaces the mechanical screen printing system with a digital printing system that uses digital inks and computer-controlled deposition, eliminating the need for physical screens and their associated changes for different designs
Solution Approach 2:
The patent changes the physical-chemical parameters of the ink (creating digital ink with specific particle size distribution, viscosity, and composition) to enable direct digital deposition on glass surfaces without requiring screen intermediaries
2Manufacturing precision
If frit is ground or milled to reduce particle size for digital ink application, then the ink can be applied digitally, but metallic contaminants from grinding equipment affect the dissolution of functional films
Solution Approach 1:
The patent extracts and removes metallic contaminants from the ground frit through magnetic separation and filtration processes, isolating the harmful metallic particles from the useful glass frit particles
Solution Approach 2:
The patent introduces organic vehicles and binders as intermediary substances that carry the ground frit particles, enabling the contaminated frit to be processed and delivered in a controlled manner that separates the contamination issue from the dissolution function
3Adaptability or versatility
If digital ink is applied on glass with functional films, then design flexibility is improved, but the ink must have very small particle size (≤3μm) which reduces its ability to dissolve thin films
Solution Approach 1:
The patent segments the ink into two functional components: fine glass frit particles (≤3μm) for digital applicability and larger ceramic pigment particles for film dissolution, with each size fraction performing its specific function
Solution Approach 2:
The patent creates a composite digital ink material combining glass frit, ceramic pigments, and organic vehicles in specific proportions, where the composite structure enables both digital applicability and film dissolution capability simultaneously
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 allows for precise application of digital inks on glass with functional films without affecting their dissolution, reducing waste and enabling flexible, efficient printing without the need for screen changes.
Implementation Method 1
A two-stage milling process using zirconia micro-bead mills to reduce particle size to 3 microns
Implementation Method 2
magnetic iron removers to reduce particle size to 3 microns
Implementation Method 3
followed by thermal calcination, ensures the ink is free of contaminants
Implementation Method 4
can accurately dissolve functional films on glass
Data Source
AI summary
Procedure for obtaining a digital ink for application on glass provided with a functional film or thin film, so that although the frit has been ground or milled to be used as digital ink this does not affect its ability to dissolve the functional film or thin film during its application and comprises the steps of: - Dispersing the frit in an organic medium. - Performing an initial wet grinding using zirconia micro-bead mills to a particle size of 2 microns. - Using an in-line iron remover to remove iron particles. - Performing a thermal process to calcine and remove all remaining contaminants present. - Once the thermal process is finished, it is subjected to a second wet milling process with zirconia micro-bead mills to a particle size between 1 and 1.7 microns.