Direct-to-Substrate Printing Assembly with Liquid Binder
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Solution Overview
Problem
Existing direct to film printing methods face challenges such as inconsistencies in film properties, lack of film reusability, complexity in powder adhesive application, and inefficiencies in image transfer and binding.
Innovation Solution
A direct-to-substrate printing assembly that includes an ink printing station, a binder application station, a curing station, and a transfer station, allowing for automated printing and transfer of images onto substrates without the need for off-line processing or powder adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If direct to film printing is used with powder adhesive, then image transfer is achieved, but the process complexity increases and inhalation risks arise
Solution Approach 1:
The patent extracts and eliminates the powder adhesive step from the direct to film printing process. The invention uses a liquid binder that is applied directly to the substrate along with the ink, removing the need for separate powder adhesive application, distribution, and curing steps. This extraction of the harmful powder adhesive component resolves the contradiction by maintaining image transfer reliability while reducing process complexity and eliminating inhalation risks.
Solution Approach 2:
The patent introduces a liquid binder as an intermediary substance that performs the adhesive function previously achieved by powder adhesive. This liquid binder is applied in liquid form, allowing for easier and more controlled application without requiring shakers or vibrating equipment. The liquid binder serves as a mediator between the ink layer and the substrate, achieving reliable image transfer while simplifying the overall process.
2Strength
If powder adhesive is used for direct to film printing, then binding is achieved, but the process becomes messier and requires special equipment
Solution Approach 1:
The patent replaces the mechanical powder distribution system (shakers, vibrating equipment) with a liquid application system. The liquid binder can be applied using conventional printing or coating methods, eliminating the need for specialized mechanical powder distribution equipment. This substitution maintains binding strength while dramatically improving ease of operation and reducing messiness.
Solution Approach 2:
The patent changes the physical state of the binder from solid powder to liquid form. This parameter change from solid to liquid state fundamentally improves ease of application, as liquids can be applied more uniformly and controllably using standard coating or printing techniques. The liquid binder maintains adequate binding strength while eliminating the operational difficulties associated with powder handling.
3Reliability
If transfer film is used in direct to film printing, then image transfer is enabled, but inconsistencies in film properties and lack of reusability occur
Solution Approach 1:
The patent eliminates the reusable transfer film concept and instead uses a disposable substrate that is discarded after a single use. Each substrate is optimized for single-use performance with consistent properties, eliminating the degradation and inconsistency that occur with repeated use of the same film. This approach ensures reliable image transfer while accepting the substrate as a consumable item rather than a reusable component.
4Reliability
If manual cutting and placement of film is used, then image transfer is achieved, but productivity decreases
Solution Approach 1:
The patent combines multiple separate operations (ink application, binder application, substrate preparation, and image transfer) into a single integrated printing process. The liquid binder is applied simultaneously with or immediately after the ink layer in the same printing operation, eliminating the need for separate cutting and manual placement steps. This merging of operations maintains reliable image transfer while dramatically improving productivity by automating the entire process.
Solution Approach 2:
The patent performs preliminary binding by applying the liquid binder to the substrate along with the ink layer before the actual transfer operation. This preliminary action ensures that the image is already bound to the substrate when transfer occurs, eliminating the need for subsequent binding steps and manual handling. The preliminary application of binder streamlines the process and improves productivity while maintaining transfer reliability.
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 solution enables efficient, automated direct-to-substrate printing with improved image transfer and binding, reducing technician time, eliminating inhalation risks, and enhancing the durability and clarity of transferred images.
Implementation Method 1
a curing station wherein the curing station is configured to cure or partially cure the ink layer and binder layer
Data Source
AI summary
A direct to substrate printing assembly including a substrate, an ink printing station wherein the ink printing station is configured to print an ink layer onto the substrate, a binder application station wherein the binder application station is configured to dispose a binder onto the ink layer, a curing station, and a transfer station wherein the assembly is configured to transfer the ink layer and the binder layer disposed on the substrate to an article and wherein the assembly is fully automated. A method of direct to substrate printing and a composition for direct to substrate printing produced therefrom are also disclosed.