Hot Melt Ink Composition for Continuous Printing
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Solution Overview
Problem
Existing inkjet printing technologies face limitations in achieving high printing quality and flexibility with conventional ink compositions, particularly in continuous printing processes, due to issues with net electric charges, viscosity, and particle size, which affect image formation and substrate interaction.
Innovation Solution
A hot melt ink composition comprising at least one wax and a conductive agent, with a conductivity of 10 µS/cm to 200 µS/cm and a density of at least 0.8 g/mL, is used in a continuous printing process to form an ink stream with no net electric charge, allowing for improved printing quality and flexibility by enabling a wider range of ingredients and properties, including larger particles and higher viscosities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional ink compositions are used in continuous printing processes, then printing can be performed, but printing quality is limited due to issues with net electric charges, viscosity, and particle size
Solution Approach 1:
The patent applies parameter changes by modifying the electrical charge state of the ink from charged to substantially neutral, and by adjusting physical parameters such as viscosity (10-10,000 cP) and particle size (1-50 μm). These parameter changes enable the ink to be used in continuous printing processes while achieving improved printing quality and allowing greater flexibility in composition, including the use of larger particles and higher viscosity materials that would not be suitable in conventional charged ink systems.
2Manufacturing precision
If hot melt ink composition is used to enable continuous printing with no net electric charge, then printing quality is improved and flexibility is increased, but the ink requires specific conductivity and density parameters to maintain jettable characteristics
Solution Approach 1:
The patent maintains reliability of jettable characteristics by establishing specific parameter ranges for the hot melt ink composition: conductivity of 10-200 μS/cm and density of at least 0.8 g/mL. These parameter changes ensure the ink remains jettable in continuous printing processes while achieving improved printing quality and composition flexibility, including the ability to incorporate larger particles and higher viscosity materials.
3Adaptability or versatility
If larger particles and higher viscosities are incorporated into the ink composition, then ingredient versatility is increased, but the ink may lose its ability to be ejected through the printhead
Solution Approach 1:
The patent resolves this contradiction by defining specific parameter ranges that enable both ingredient versatility and jettable characteristics: viscosity of 10-10,000 cP and particle size of 1-50 μm. These parameter changes allow the incorporation of larger particles and higher viscosity materials while maintaining the ability to eject through the printhead in continuous printing processes, achieving both versatility and operational ease.
4Adaptability or versatility
If the distance between printhead and substrate is increased, then printing flexibility is improved, but conventional inks may not maintain proper droplet formation and image quality
Solution Approach 1:
The patent enables increased distance between printhead and substrate by changing the electrical charge parameter of the ink to substantially neutral, eliminating the need for precise charge control that is required in conventional charged ink systems. This parameter change allows greater distance flexibility while maintaining proper droplet formation and image quality, as the neutral charge reduces electrostatic interference and allows for more flexible positioning.
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 hot melt ink composition enables improved printing quality, allows for a larger distance between the printhead and substrate, and accommodates a wider range of ingredients and properties, including higher viscosities and larger particles, while maintaining jettable characteristics, enhancing the formation of images and 3-D articles.
Implementation Method 1
The hot melt ink composition includes at least one wax and at least one conductive agent. The composition has a conductivity of from about 10 μS/cm to about 200 μS/cm in a melted state
Implementation Method 2
Hot melt inks are a solid at ambient temperature and a liquid at temperatures above ambient temperature. During printing, the ink is typically heated until it becomes a liquid which is then ejected through a printhead onto a substrate
Data Source
Figure 1A
Figure 1B
AI summary
This disclosure relates to an ink composition (e.g., a hot melt ink composition or a radiation curable ink composition) that has a relatively low conductivity. This disclosure also relates to a continuous printing process using such a composition and a product containing such a composition.