Multilayer inkjet printing on dark substrate using white opaque ink and translucent colored inks
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Solution Overview
Problem
Conventional color printing techniques require printing multiple layers of white ink on nonwhite substrates to achieve color accuracy, which increases printing time, ink usage, and costs, and results in high contrast when the printed color is scratched or damaged, exposing underlying white layers.
Innovation Solution
A method of hot-melt printing that uses intermixed translucent color inks and opaque white inks in multiple layers with varying ratios, allowing color-accurate printing directly on nonwhite substrates without the need for a white substrate, reducing the number of printed layers and ink usage, and enhancing color durability by distributing color throughout the layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple layers of white ink are printed on nonwhite substrates to achieve color accuracy, then color accuracy is improved, but printing time and ink usage increase
Solution Approach 1:
The invention changes the parameter of ink composition by using translucent color inks mixed with opaque white ink in varying ratios across different printed layers. This parameter change allows color accuracy to be achieved without requiring multiple pure white layers, thereby reducing printing time while maintaining color fidelity on nonwhite substrates.
Solution Approach 2:
The invention creates a composite ink system by combining translucent color inks with opaque white ink in different proportions across multiple layers. This composite approach allows the printed layers to collectively achieve both color accuracy and reduced printing time, as the varying ratios of white to color ink in each layer optimize both objectives simultaneously.
2Manufacturing precision
If multiple layers of white ink are printed on nonwhite substrates to achieve color accuracy, then color accuracy is improved, but ink usage and costs increase
Solution Approach 1:
The invention optimizes ink usage by changing the composition parameters of each printed layer, using varying ratios of opaque white ink to translucent color ink. This allows color accuracy to be achieved with reduced overall ink consumption, as the translucent color inks contribute to color accuracy without requiring complete coverage by white ink in every layer.
Solution Approach 2:
The composite ink system combining translucent color inks with opaque white ink in varying ratios enables efficient ink utilization. The translucent color inks provide color information that accumulates across layers, reducing the need for excessive white ink application while maintaining color accuracy, thereby lowering ink usage and associated costs.
3Manufacturing precision
If multiple layers of white ink are printed on nonwhite substrates, then color accuracy is improved, but high contrast damage occurs when printed color is scratched
Solution Approach 1:
The invention changes the parameter of ink translucency by using translucent color inks instead of opaque inks in the colored layers. This allows the color to be distributed throughout multiple layers with varying white ink content, so that when scratched, the underlying layers still contain color information, reducing the visibility of damage while maintaining color accuracy.
Solution Approach 2:
The composite structure of printed layers with varying ratios of opaque white ink and translucent color ink creates a gradient of color distribution. When scratched, the translucent color ink in underlying layers becomes visible, providing a gradual transition rather than abrupt white exposure, thereby reducing the harsh contrast of damage while preserving color accuracy.
4Productivity
If the number of printed layers is reduced, then printing time and ink usage decrease, but color accuracy and durability are compromised
Solution Approach 1:
The invention optimizes the parameters of each printed layer by using varying ratios of opaque white ink to translucent color ink. This allows a reduced number of layers to achieve the same color accuracy as more layers would provide with uniform composition, thereby improving printing efficiency without sacrificing color fidelity or durability.
Solution Approach 2:
The composite ink system with varying white-to-color ratios across layers creates a more efficient color buildup than uniform layers. This allows color accuracy and durability to be achieved with fewer printed layers, as each layer contributes optimally to the final color result, improving printing efficiency while maintaining 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 method achieves color accuracy and durability by building opacity through intermixed inks, reducing visible damage when scratched, and extending the lifespan of printed colors, with improved abrasion resistance and lower printing costs.
Implementation Method 1
printing a melt of an opaque material and at least one translucent pigmented material onto a substrate
Data Source
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AI summary
A method of hot-melt printing, comprising: printing a melt of an opaque material and at least one translucent pigmented material onto a substrate, the opaque material and the at least one translucent pigmented material being supplied from different printheads. The opaque material and the at least one translucent pigmented material mix on the substrate. The printing further comprises: printing at least one color comprising multiple printed layers of the opaque material and the at least one translucent pigmented material. The multiple printed layers comprises: at least a first layer comprising the opaque material and the at least one translucent pigmented material, the first layer having a predetermined first ratio of opaque material to translucent pigmented material; and at least a second layer comprising the opaque material and the at least one translucent pigmented material, the second layer having a predetermined second ratio of opaque material to translucent pigmented material different from the first ratio. The first ratio is greater than the second ratio.