Pigment Fragment Transfer for High-Purity Complex Contours
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Solution Overview
Problem
Existing methods for producing pigments with predetermined contours are inefficient and costly, particularly when attempting to create complex shapes or sizes, and often result in low purity and breakage during the manufacturing process.
Innovation Solution
A process involving a pigment layer adhering to an intermediate substrate, separated from a starting substrate, which is structured into pigments with predefined contours, protecting them from breakage and ensuring high purity by retaining residual sections on the starting substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the pigment layer is detached and ground into small fragments using conventional methods, then pigments are produced, but the shape and size are not precisely defined and breakage occurs during processing
Solution Approach 1:
The pigment layer is pre-structured with the desired contour pattern before detachment. This preliminary structuring ensures that when the layer is detached and broken, the pigments already have the predetermined shape and size, eliminating the need for post-processing grinding and achieving both precision and integrity
Solution Approach 2:
An intermediate substrate is introduced between the starting substrate and the final pigment product. The pigment layer is detached from the starting substrate and transferred to the intermediate substrate, which protects the structured pigment sections during handling and processing, preventing breakage while maintaining precision
2Adaptability or versatility
If embossing or lasering is used to structure pigment layers with predetermined contours, then complex shapes can be achieved, but the production process becomes costly and time-consuming
Solution Approach 1:
The patent replaces complex mechanical embossing or lasering processes with a simpler detachment and breaking mechanism. By pre-structuring the pigment layer and then detaching it from the substrate, the desired complex contours are achieved through the breaking pattern rather than through complex forming operations, significantly improving production efficiency
Solution Approach 2:
The pigment layer is divided into multiple sections with different contours during the detachment process. This segmentation allows different complex shapes to be produced simultaneously from a single continuous layer, increasing versatility without reducing productivity
3Manufacturing precision
If the pigment layer is broken down into pigments, then pigments are produced, but purity is low due to contamination with fragments
Solution Approach 1:
The intermediate substrate acts as a mediator that separates the structured pigment sections from the residual sections. When the pigment layer is detached, the intermediate substrate captures the pigments with predetermined contours while leaving fragments on the starting substrate, enabling easy separation and high purity
Solution Approach 2:
The desired pigment sections are extracted from the pigment layer by selective detachment to the intermediate substrate. This extraction process separates the useful pigments with defined contours from the unwanted residual sections and fragments, achieving both contour precision and high purity
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
Enables the production of pigments with complex outer and inner contours in high purity, allowing for smaller sizes and thicknesses with increased reliability, and reduces material waste by reusing substrates.
Implementation Method 1
The pigment layer adheres to the intermediate substrate at least in sections
Data Source
Figure 1a~2c
Figure 3~4
Figure 5~6
AI summary
A method for producing pigment fragments (1) with a predefined contour comprises the steps: - creating a pigment layer (210) on a starting substrate (20); detachment from the starting substrate (20); and structuring the pigment layer (210) to form a plurality of pigment fragments (1); characterised by the pigment layer (210) being brought into contact with an intermediate substrate (31), wherein at least part of the pigment layer (210) adheres to the intermediate substrate (31); and by the separation of the intermediate substrate (31) and the starting substrate (21).