Continuous Fabric Digital Printing With In-Line Drying
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Solution Overview
Problem
Conventional digital printing and finishing methods for fabrics are limited by independent sequential steps, resulting in low productivity and prolonged processing times, which are not adequately addressed by attempts to combine washing and drying steps.
Innovation Solution
A continuous method involving unwinding, speed compensation, digital printing on a conveyor belt with synchronized piezoelectric ink jet printing heads, followed by drying and winding, with optional immersion in a solution for ink fixation, and reduced steaming time to enhance productivity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional digital printing and finishing method with independent sequential steps is used, then printing quality can be maintained, but productivity is limited and processing time is prolonged
Solution Approach 1:
The patent implements a continuous printing system where fabric moves continuously through the printing station on a conveyor belt, eliminating the stop-start nature of conventional methods. The piezoelectric ink jet heads print continuously as fabric passes by, and drying occurs in-line without removing the fabric from the production line, maintaining continuous useful action throughout the process.
Solution Approach 2:
The patent merges multiple independent steps (printing, drying, and finishing) into a single continuous in-line process. The printing station, drying chamber, and finishing operations are combined in sequence with the fabric moving continuously through all stages without interruption or manual intervention between steps.
2Speed
If washing and drying steps are performed continuously, then processing speed is partially improved, but productivity remains insufficient
Solution Approach 1:
The patent applies preliminary action by pre-treating the fabric with hydrophilic substances before printing to enhance ink penetration and fixation. This preparation is done in-line before the printing operation, allowing the subsequent printing and drying to proceed more efficiently without requiring separate extended processing steps.
Solution Approach 2:
The system maintains continuous operation through automated fabric feeding, continuous printing head operation, in-line drying, and automatic rewinding. The conveyor belt system ensures uninterrupted fabric movement through all processing stages, eliminating idle time and maintaining maximum productivity throughout the entire operation.
3Ease of operation
If manual intervention is reduced, then operational simplicity and safety improve, but system complexity increases
Solution Approach 1:
The system is designed to be self-operating with automated fabric feeding from the first reel, automatic conveyor belt movement, electronically controlled printing heads that self-synchronize with fabric speed, automated drying, and self-powered rewinding on the second reel. Once started, the system performs all operations without manual intervention, making it easy to operate despite the sophisticated mechanisms involved.
Solution Approach 2:
The patent incorporates electronic synchronization between the conveyor belt movement and the piezoelectric ink jet printing heads. The system uses feedback mechanisms to monitor fabric speed and position, automatically adjusting the printing head operation to maintain precise alignment and printing quality without manual intervention.
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 method significantly reduces processing times, increases productivity, minimizes manual intervention, and offers improved reliability and safety while reducing energy consumption and production costs.
Implementation Method 1
transversely to said conveyor belt there being a plurality of bars provided with printing heads which are controlled electronically and synchronized with the movement of said conveyor belt
Implementation Method 2
a step of drying said fabric
Data Source
AI summary
A method of digital printing and finishing for fabrics is provided. The method includes a step of unwinding a fabric from a first reel. A step of compensating the speeds and of spreading the fabric for its positioning on a conveyor belt provided with supporting elements on which a digital printing step occurs is provided. A step of drying the fabric is provided. A step of winding the fabric onto a second reel is provided. These steps are being executed at corresponding stations arranged in sequence with respect to each other and the fabric passing through them continuously, transversely to the conveyor belt, there being a plurality of bars provided with printing heads which are controlled electronically and synchronized with the movement of the conveyor belt.