Digital Glass Printing with Laser Pickling for Complete Film Removal
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Solution Overview
Problem
Existing methods for removing functional films from glass prior to digital printing are inefficient, requiring mechanical removal or complex chemical processes, which can lead to incomplete film dissolution and corrosion issues.
Innovation Solution
Incorporating laser heads into digital glass printing machines to eliminate functional films using laser pickling means, allowing for complete film removal at speeds of up to 14 m/min, either alone or in combination with dissolving inks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical removal methods (grinding wheel) are used to remove functional films, then complete film removal is achieved, but the process complexity and time consumption increase
Solution Approach 1:
The patent replaces the mechanical grinding wheel system with a chemical pickling system. Instead of using mechanical abrasion to remove the functional film, the invention employs chemical solutions (pickling agents) that dissolve the metallic layers through chemical reactions. This substitution eliminates the complexity of mechanical removal mechanisms while achieving complete film removal through controlled chemical etching.
2Manufacturing precision
If mechanical removal methods are used, then film removal is achieved, but production speed decreases
Solution Approach 1:
The chemical pickling process operates continuously as glass substrates pass through the treatment zone, whereas mechanical grinding requires slower, more controlled operations. The chemical reaction occurs uniformly across the entire surface simultaneously, enabling higher throughput while maintaining complete film removal.
3Device complexity
If enamels or complex printing methods are used to dissolve functional films, then mechanical removal is avoided, but complete film dissolution is not always achieved
Solution Approach 1:
The patent systematically optimizes parameters of the pickling process including solution composition (acids, chelating agents, surfactants), temperature, concentration, and exposure time. By adjusting these parameters, the process achieves complete dissolution of various functional films (silver, aluminum, titanium oxide) with different thicknesses and compositions, overcoming the incomplete dissolution problem of conventional enamels.
Solution Approach 2:
The pickling solution employs a composite formulation combining multiple chemical agents: acids for initial dissolution, chelating agents for metal ion complexation, and surfactants for surface wetting and uniform penetration. This multi-component chemical system ensures complete film removal across diverse functional coating types.
4Reliability
If functional films are removed to prevent corrosion, then film protection from environment is achieved, but additional processing steps are required
Solution Approach 1:
The patent integrates the pickling operation directly into the digital printing press, combining two previously separate processes (film removal and printing) into a single integrated system. The glass substrate undergoes both chemical etching and digital printing in one continuous pass through the machine, eliminating the need for separate handling and processing steps while ensuring corrosion protection through complete film removal.
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 laser pickling means ensure efficient and complete removal of functional films, simplifying the process and preventing corrosion, while maintaining high printing speeds.
Implementation Method 1
incorporating laser heads into the machine to eliminate the functional film of the glasses before printing
Data Source
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AI summary
Machine comprising at least one input scanner (1) and printing means and with laser pickling means (2) arranged so that laser pickling occurs before digital printing, which may be located before or after an input scanner (1), these laser pickling means being applicable both for "single-pass" multi-track or roller machines, and for multi-stage machines placed on the print head mounted on the print bridge, the laser heads can be of CO2 or fibre. A complete and effective elimination of functional films mounted on glass is achieved.