Method for manufacturing dye-attached substrate and printing device
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Solution Overview
Problem
The existing methods for manufacturing dye-attached substrates used in resin dyeing processes face inefficiencies due to issues like substrate curling, clogging, and color inconsistencies, which hinder the ability to efficiently produce substrates with precise color matching and high work efficiency.
Innovation Solution
A method and device that arranges a roll-shaped substrate to prevent curling, uses multiple ink heads to select suitable inks based on resin characteristics, and prints and cuts substrates in units to enhance efficiency and color accuracy, including a printing device with ink heads, a cutter, and a processor for controlling the printing and cutting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If substrates are precut into predetermined sizes before printing, then each substrate can be processed individually, but work efficiency deteriorates due to the need to perform various subsequent operations for each substrate separately
Solution Approach 1:
The substrate is divided into multiple units in the longitudinal direction, with each unit containing one or more dye sections for dyeing one resin body or one set of resin bodies. This segmentation allows the substrate to be processed as a single continuous piece while still enabling individual dyeing operations for each unit, thereby improving work efficiency without sacrificing individual processing capability
Solution Approach 2:
Multiple dye sections are combined on a single continuous substrate, allowing multiple resin bodies to be dyed from one substrate piece. This merging approach enables batch processing where multiple units are printed and dried simultaneously on one substrate before cutting, significantly improving productivity while maintaining the ability to process each unit individually
2Productivity
If multiple dye sections are printed on a single substrate, then work efficiency improves through simultaneous production, but manufacturing precision deteriorates due to potential color inconsistencies across multiple units
Solution Approach 1:
Each dye section on the substrate is treated as a local unit with its own ink discharge control. The printing device discharges ink for each dye section independently based on the resin body characteristics and desired color, ensuring that each unit achieves precise color matching while multiple units are produced simultaneously on the same substrate
Solution Approach 2:
The system uses feedback control where the printing device adjusts ink discharge for each dye section based on resin body characteristics and color requirements. This feedback mechanism ensures consistent color quality across multiple units printed on a single substrate, maintaining manufacturing precision while improving productivity
3Loss of substance
If the substrate is made long and thin to accommodate multiple units, then material waste reduces through better utilization, but device complexity increases due to the need for precise cutting and handling
Solution Approach 1:
The substrate is prepared in advance as a continuous long thin piece with multiple dye sections printed and dried on it before cutting. This preliminary action of printing and drying multiple units on one substrate reduces material waste by maximizing substrate utilization, and the cutting operation is simplified to just dividing the already-prepared substrate into individual units with required margins
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 prevents substrate curling and clogging, ensures accurate color deposition, and increases work efficiency by allowing for the simultaneous production of multiple units on a single substrate, reducing material waste and improving color consistency.
Implementation Method 1
a sublimable dye that is adhered to a to-be-dyed substrate is heated, and the heated sublimable dye is deposited on a resin body
Data Source
AI summary
A method for manufacturing a dye-attached substrate provided with a dye section that includes a sublimable dye to be deposited on a resin body includes a printing step of printing a plurality of units of the dye sections, the dye section for dyeing one resin body or one set of resin bodies constituting one unit, lined up in a longitudinal direction of a long thin substrate, by discharging ink that includes the sublimable dye on the substrate using a printing device, a piece creating step of creating a piece of the substrate that includes the plurality of units of the dye sections, by cutting the substrate on which the dye section is printed, and a drying step of drying the ink of the plurality of units of the dye sections included in the piece of the substrate.