High-Viscosity Pigmented Ink for Bleed-Resistant Decorative Sheets
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Solution Overview
Problem
Existing methods for manufacturing decorative panels face issues with ink bleeding and nozzle clogging due to low viscosity inks, leading to reduced printing quality and increased material costs, especially in digital printing processes.
Innovation Solution
Using high viscosity pigmented inks with a viscosity above 30 mPas, preferably above 40 mPas, applied through digital printing, reduces the need for ink receiver layers and improves printing quality by minimizing ink absorption and lateral spreading, thereby enhancing resolution and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If low viscosity pigmented inks are used in digital printing, then the ink can be easily applied and spread, but the ink bleeds during resin impregnation and causes nozzle clogging
Solution Approach 1:
The patent changes the viscosity parameter of the pigmented ink from conventional low viscosity to high viscosity (above 30 mPas). This parameter change prevents ink bleeding during resin impregnation and eliminates nozzle clogging, while still allowing the ink to be applied effectively through digital printing processes.
2Manufacturing precision
If ink receiver layers are applied to reduce ink bleeding, then printing quality improves, but lamination issues arise and printer nozzles clog
Solution Approach 1:
The patent extracts and eliminates the ink receiver layer from the printing process. By using high viscosity pigmented inks, the ink maintains its position during resin impregnation without requiring an additional ink receiver layer, thereby simplifying the overall process and avoiding lamination and nozzle clogging issues.
Solution Approach 2:
Instead of adding an ink receiver layer to control ink behavior, the patent inverts the approach by modifying the ink itself (increasing its viscosity) to inherently resist bleeding. This eliminates the need for additional layers and simplifies the process.
3Productivity
If direct digital printing is applied to thermoplastic foils, then production efficiency increases, but ink droplets spread laterally reducing resolution
Solution Approach 1:
The patent applies high viscosity pigmented inks (above 30 mPas) which resist lateral spreading on thermoplastic foils. This allows direct digital printing to be used on thermoplastic substrates while maintaining high resolution, as the viscous ink remains confined to the printed areas without bleeding laterally.
4Quantity of substance
If conventional pigmented inks are used, then material costs are lower, but ink bleeding requires additional ink receiver layers increasing costs
Solution Approach 1:
The patent uses high viscosity pigmented inks that inherently control ink placement without requiring additional ink receiver layers. This eliminates the need for extra materials while maintaining ink control, thereby reducing overall material costs despite the higher viscosity ink formulation.
Data Source
AI summary
A method for manufacturing a decorative sheet for making decorative panels may involve providing a sheet, preferably a paper layer or a thermoplastic foil. A printed motif may be applied to the sheet by means of digital printing. The printed motif may be applied using a pigmented ink. The pigmented ink may have a viscosity above 30 mPa·s, preferably above 40 mPa·s. Decorative sheets may be obtained by the method. A method may be provided for manufacturing a decorative panel that includes the decorative sheet.