Dry Ink Digital Printing Resolves Nozzle Clogging and Cost
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Solution Overview
Problem
Conventional digital printing methods for flooring are limited by high ink costs, nozzle clogging issues, and the need for protective layers that are costly and not completely transparent, which restricts the flexibility and cost-effectiveness of creating high-quality, wear-resistant digital images on large panels.
Innovation Solution
A two-step process involving the separate application of a liquid binder and dry pigment-based particles, where the particles are bonded to the surface using a digital print head to form a high-definition pattern, followed by pressing and curing to create a hard, wear-resistant layer, eliminating the need for expensive ink and reducing nozzle clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional digital printing methods use liquid ink with pigments, then color application is achieved, but nozzle clogging occurs and ink costs are high
Solution Approach 1:
The patent separates the printing process into two independent steps: first applying a liquid binder without pigments, then applying dry pigment-based particles. This segmentation eliminates pigment from the liquid ink system, preventing nozzle clogging while reducing ink costs since only the binder is applied digitally.
Solution Approach 2:
The patent extracts the pigment component from the liquid ink formulation, applying it separately as dry particles after the binder is deposited. This extraction resolves the nozzle clogging issue by removing solid particles from the liquid stream while maintaining color application capability.
2Strength
If expensive protective layers are applied over digital prints, then wear resistance is improved, but transparency and cost are compromised
Solution Approach 1:
The patent merges the protective function with the pigment particles themselves by using resin-coated particles that are pressed into the surface and cured to form a hard, wear-resistant layer. This eliminates the need for separate protective overlays, maintaining transparency while reducing costs.
Solution Approach 2:
The patent changes the physical and chemical parameters of the pigment particles by coating them with resin and then applying heat and pressure to cure the resin, transforming soft pigment particles into a hard, wear-resistant surface layer that serves both decorative and protective functions.
3Manufacturing precision
If liquid ink is used for digital printing, then color application is achieved, but the final wear-resistant layer requires additional protective coatings
Solution Approach 1:
The patent utilizes phase transitions by applying dry pigment particles that are then pressed and cured under heat and pressure, transforming them from a loose particulate state to a solid, integrated layer within the flooring material. This eliminates the need for additional protective liquid coatings.
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 method allows for cost-effective, high-quality, multi-color digital printing with improved wear resistance and flexibility, enabling realistic wood and stone designs without the use of expensive ink or protective layers.
Implementation Method 1
the dry resin is adapted to melt when the macro colourant is in contact with the liquid print and to bond the macro colourant to the surface
Implementation Method 2
a liquid binder and dry pigment-based particles, where the particles are bonded to the surface using a digital print head
Implementation Method 3
followed by pressing and curing to create a hard, wear-resistant layer
Data Source
Figure 1a~1e
Figure 2a~2e
Figure 3a~3d
AI summary
The disclosure relates to pigment based particles in powder form intended to be used as colourants (7) in a digital print formed by applying dry colourants (7) on a surface (2), bonding a part of the colourants (7) with a binder (11) and removing the non-bonded colourants (7) from the surface (2). A panel (1) with a surface (2) including a digitally formed print of macro colourants (64) including a particle body (66) and colour pigments (12) attached to the surface of the particle body (66) is also described. The colourants (7) are arranged in patterns with pigments (12) on an upper and lower surface of the particle body (66).