Inkjet Printing Catalyst Separation for Rapid Curing
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Solution Overview
Problem
Conventional digital inks used in inkjet printing face issues with slow curing times and image degradation, especially when printing on unconventional substrates like textiles and glass, due to the use of organic solvents and water-based inks, which can lead to premature curing and nozzle clogging, as well as bleeding or running on substrates.
Innovation Solution
The method involves using an inkjet head that separates digital ink and catalyst until they are discharged, allowing them to combine on the substrate for rapid curing, utilizing self-initiating or thermally reactive catalysts to accelerate the curing process without premature gelation within the inkjet head, and employing water-based inks with cross-linkable resins and pigments to achieve high-quality, durable prints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If water-based inks are used instead of organic solvents, then environmental compliance and safety are improved, but curing time increases and image quality degrades due to bleeding
Solution Approach 1:
A catalyst is introduced as an intermediary substance that accelerates the curing reaction of water-based inks. The catalyst enables rapid curing without requiring organic solvents, thus maintaining environmental compliance while solving the slow curing time problem. The catalyst is applied either before or after ink deposition to initiate cross-linking reactions that quickly set the water-based ink.
2Loss of time
If accelerators are added to digital inks to speed up curing, then curing time is reduced, but the ink becomes unstable and may prematurely cure or gel inside the inkjet head
Solution Approach 1:
The system separates the ink and catalyst into distinct components that are stored and transported separately. The ink is kept in the inkjet head while the catalyst is applied separately (either before ink deposition through a separate nozzle or after ink drying). This segmentation prevents premature mixing and premature curing/gelling inside the inkjet system, maintaining ink stability while enabling rapid curing when the catalyst contacts the deposited ink.
3Ease of operation
If low viscosity ink is used to facilitate flow through small nozzles, then ease of printing is improved, but image quality degrades due to bleeding or running on substrate
Solution Approach 1:
The catalyst is applied to the substrate before the ink is deposited. This preliminary application creates a pre-conditioned surface that promotes rapid curing upon ink contact. The low viscosity ink flows easily through the nozzle and deposits on the catalyst-prepared surface, where it quickly cures before it can bleed or run, thus maintaining both ease of printing and image quality.
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 enables rapid curing of digital inks on a variety of substrates, preventing image degradation and nozzle clogging, while maintaining high print quality and durability, even on unconventional surfaces, with the inkjet head capable of producing high-resolution images.
Implementation Method 1
an effective amount of a catalyst is applied to the substrate prior to application of the digital ink or is applied over the digital ink subsequent to its application to the substrate. The catalyst accelerates the curing of the digital ink on the substrate.
Implementation Method 2
The digital ink includes a cross-linkable resin having at least one reactive site
Data Source
AI summary
Systems and methods for digitally printing images onto substrates are provided using digital inks and catalysts which initiate and/or accelerate curing of the inks on the substrates. The ink and catalyst are kept separate from each other while inside the heads of an inkjet printer and combine only after being discharged therefrom. The system produces high-quality, high-resolution images on substrates that may not normally receptive to low-viscosity digital inks.