Digital Injection Print Ink Cost and Clogging
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Solution Overview
Problem
Existing digital printing technologies for decorative surfaces on building panels, such as floors and walls, face challenges including high ink costs, nozzle clogging, and the need for protective layers that are costly and not completely transparent.
Innovation Solution
A method and equipment that apply and bond powder-based colorants using a digital injection print (DIP) process, where ink is injected into a powder layer and cured, eliminating the need for liquid ink and protective layers, and allowing for increased wear resistance and flexibility in design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If liquid ink is used in digital printing, then colorants can be applied to the surface, but ink costs are high and nozzles clog
Solution Approach 1:
The patent changes the physical state of the colorant from liquid to powder form. This parameter change eliminates nozzle clogging issues associated with liquid ink while significantly reducing material costs. The powder colorants are applied through a different mechanism that does not involve traditional inkjet nozzles.
Solution Approach 2:
The patent uses a digital image to control the placement of powder colorants, creating a digital print copy on the surface. This approach replicates the functionality of traditional digital printing but uses powder instead of liquid ink, avoiding clogging and reducing costs.
2Strength
If protective layers are applied over digital prints, then wear resistance is improved, but transparency is reduced and costs increase
Solution Approach 1:
The patent merges the decorative print and protective wear layer into a single integrated layer. Powder colorants are applied to a powder-based surface and then cured together, eliminating the need for separate protective overlays. This integration maintains full transparency while providing wear resistance.
Solution Approach 2:
The patent uses a composite powder-based system combining colorants and surface material that are cured together. This composite approach creates an inherent protective layer within the surface structure itself, rather than adding a separate protective coating, thus maintaining transparency while providing durability.
3Ease of manufacture
If conventional digital printing is used, then decorative surfaces can be created, but separate protective layers are required which increase cost and reduce transparency
Solution Approach 1:
The patent combines the printing and protective layer application into a single simultaneous process. Powder colorants are applied and cured with the surface material in one step, eliminating multiple process steps and reducing manufacturing complexity despite improving overall production capability.
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 DIP method reduces ink costs, prevents nozzle clogging, and achieves high wear resistance without separate protective layers, while also allowing for advanced designs and increased productivity in digital printing.
Implementation Method 1
applying drops of a blank ink by a digital drop application head on the surface
Implementation Method 2
applying drops of a blank ink by a digital drop application head on the surface
Implementation Method 3
The surface with the attached colourants is pressed and cured
Implementation Method 4
The surface with the attached colourants is pressed and cured
Data Source
AI summary
A method, a panel and equipment to form a digital print by applying dry ink, preferably including particles of pigment coated wood fibres, on a surface, bonding a part of the particles with a liquid blank ink drops and removing the non-bonded particles from the surface. A panel having a surface with a wood grain décor, the panel including a first surface portion that is formed by a continuous basic layer including wood fibres having a first color, and a second surface portion that is formed by wood fibres having a second color, wherein the wood fibres having the second color are applied on and bonded to the continuous basic layer, and wherein the second surface portion covers a part of the first surface portion.