Digital Printing Composite Articles with Pigment Layers

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Solution Overview

Problem

Existing composite articles comprising pigments and polymers often have poor mechanical properties and involve undesirable purging steps, particularly in the formation process.

Innovation Solution

The development of composite articles and methods involving a substrate with layers of pigments and polymers, where the polymer penetrates into the substrate or forms islands on the surface, utilizing digital printing systems and spray print heads to deposit curable compositions that are partially cured before contact, enabling rapid, precise, and high-throughput manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional methods of forming composite articles with pigments and polymers are used, then the manufacturing process is simple, but the mechanical properties are poor and purging steps are required

Engineering Contradiction:

Improvemechanical propertiesVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The manufacturing process is divided into discrete digital printing operations where pigment particles are deposited first, followed by polymer deposition and curing. This segmentation allows precise control over material distribution and eliminates the need for purging steps while improving mechanical properties through controlled layering.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the physical and chemical parameters of the polymer material, including its viscosity, curing characteristics, and adhesion properties, to optimize the composite article formation. These parameter changes enable better mechanical properties without requiring complex purging procedures.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If digital printing systems with curable compositions are used, then manufacturing precision and productivity are improved, but the device complexity increases

Engineering Contradiction:

Improvedeposition precisionVSAvoidsystem complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical mixing and deposition systems with a digital printing system that uses computer-controlled dispensing of curable compositions. This substitution enables precise control over material placement and curing, achieving high manufacturing precision despite increased system complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes phase transitions of curable compositions, particularly the transition from liquid to solid through UV curing or other curing mechanisms. This allows the material to be deposited in a controllable liquid state and then rapidly固化 into a stable, precise structure, enhancing manufacturing precision.

Inventive Principle:

Principle #36Phase transitions

3Strength

If polymer penetration into substrate is achieved, then adhesion and mechanical properties are enhanced, but the processing difficulty increases

Engineering Contradiction:

ImproveadhesionVSAvoidprocessing ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent applies preliminary actions by treating the substrate surface or modifying the polymer composition before deposition to facilitate penetration and adhesion. This preliminary preparation reduces processing difficulty during the actual manufacturing step while ensuring enhanced adhesion properties.

Inventive Principle:

Principle #10Preliminary action

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 enhances the mechanical properties of the composite articles while eliminating undesirable purging steps, allowing for the creation of articles with improved mechanical and aesthetic qualities, such as enhanced abrasion resistance and uniformity.

Implementation Method 1

a compressed gas source configured to atomize a fluid flowing through the mixing chamber

Methodology Applied

Scientific EffectAtomization:

Implementation Method 2

a print head configured to deposit a curable composition onto a substrate at a first location

Methodology Applied

Scientific EffectDigital printing deposition:

Implementation Method 3

a source of light and/or heat configured to cure the curable composition at a second location

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Implementation Method 4

The digital printing system may be configured to translate the substrate through the digital printing system along a pathway comprising at least the first location and the second location

Methodology Applied

Scientific EffectConveyance:

Data Source

PatentUS11230131B2Printed polymeric articles, systems and methods

Publication Date: 2022.01.25 KORNIT DIGITAL TECHNOLOGIES LTD

AI summary

Composite articles, and associated methods and systems, are generally provided.