Method for producing a heat-stable coating by digital printing
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Solution Overview
Problem
Conventional methods for applying heat-stable coatings on small household equipment, such as screen printing, spraying, and roller techniques, face issues with non-localized deposition, material wastage, and poor homogeneity, requiring multiple layers and dryers, and inkjet technology necessitates numerous passes to achieve sufficient thickness.
Innovation Solution
A digital printing method using a composition with a dry extract greater than or equal to 15% by weight, applied through nozzles with an orifice size of at least 100 μm, allowing for controlled, non-contact deposition of a thermostable coating directly onto the substrate without the need for printing forms, significantly reducing the number of layers and drying steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional spray or curtain techniques are used to apply coating, then coating coverage is achieved, but material loss increases due to overspray and deposition homogeneity deteriorates
Solution Approach 1:
The coating application is segmented into localized digital printing operations rather than continuous spray/curtain coverage. Each region receives coating only where needed, eliminating overspray waste and enabling precise control of deposition thickness and homogeneity across different areas of the substrate.
Solution Approach 2:
The patent applies local quality by enabling different coating thicknesses and compositions in different regions of the substrate through digital printing control. This allows optimized material usage in each zone while maintaining overall coating homogeneity where required, directly addressing the overspray and uniformity issues of conventional methods.
2Manufacturing precision
If conventional inkjet technology is used to apply coating, then localized deposition control is improved, but the number of printing passes increases to achieve sufficient coating thickness
Solution Approach 1:
The patent changes the parameter of composition concentration by using highly concentrated binder compositions with dry extract ≥15%. This allows achieving sufficient coating thickness in fewer printing passes while maintaining localized deposition control, directly resolving the productivity issue with conventional inkjet methods.
Solution Approach 2:
The patent applies preliminary action by pre-concentrating the binder content in the composition before application. This preliminary concentration of active material means fewer subsequent application passes are needed to reach target coating thickness, improving productivity while preserving digital printing's localized control advantages.
3Quantity of substance
If contact printing techniques like roller or screen printing are used, then coating deposition is achieved, but the process complexity increases due to required dryers between deposition steps and printing forms
Solution Approach 1:
The patent replaces mechanical contact printing systems (rollers, screens) with non-contact digital printing. This substitution eliminates the need for physical printing forms and inter-layer drying infrastructure, reducing device and process complexity while maintaining coating deposition capability.
Solution Approach 2:
The patent extracts and removes the unnecessary elements of contact printing - the printing forms (rolls, screens, plates) and the inter-layer drying steps. By using digital printing with concentrated compositions, these components are taken out of the process, simplifying the overall system while achieving the same coating deposition function.
4Manufacturing precision
If multiple layers are deposited to achieve sufficient coating thickness, then coating adequacy is improved, but the number of drying steps and production time increases
Solution Approach 1:
The patent changes the composition parameter by increasing binder concentration to dry extract ≥15%. This parameter change allows achieving adequate coating thickness in fewer layers, directly reducing the number of drying steps and production time while maintaining coating quality and thickness adequacy.
Solution Approach 2:
The patent applies preliminary action by pre-concentrating the binder content before application. This means the coating material is prepared in advance with optimal concentration, enabling fewer application and drying cycles to reach target thickness, thus reducing production time while ensuring coating adequacy.
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 precise, homogeneous coating with reduced material loss and labor, allowing for both thin and thick coatings, while eliminating the need for printing forms and inter-layer drying, facilitating high-speed production with minimal operator contact.
Implementation Method 1
the deposition is carried out by digital printing through at least one nozzle having an orifice of a size greater than or equal to 100 μm
Implementation Method 2
baking said coated substrate
Data Source
Figure 1~3
AI summary
The invention relates to a method for producing a small heating household appliance article having a substrate with at least two opposite faces, the method comprising providing said substrate and obtaining a heat-stable coating on said substrate. Said step for obtaining a coating comprises depositing by digital printing, on at least one of the two opposite faces of said substrate and through at least one nozzle having an aperture of at least 80 µm, at least one layer of a composition comprising at least one binder and having a dry extract of at least 15% by weight, and curing said coated substrate.