Digital Imaging of Polyamide Flooring Without Washing
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Solution Overview
Problem
Current methods for coloring and imaging fibrous flooring materials, such as wet dyeing and mechanical jetting, result in high energy consumption, excessive water usage, low printing resolution, and environmental pollution due to the use of high viscosity inks and chemicals, which are not environmentally friendly.
Innovation Solution
A method using low viscosity aqueous acid dyes with a piezoelectric drop-on-demand printing technique that eliminates the need for washing and achieves high-resolution color imaging on fibrous flooring materials without excessive colorants, employing a conveyor belt and steaming for curing, allowing for efficient and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high viscosity paste is used for mechanical jetting or discharging, then color imaging can be achieved on fibrous flooring materials, but excessive amount of colorants and gels are required leading to high water consumption and energy usage for washing
Solution Approach 1:
The patent changes the viscosity parameter of the ink from high (paste) to low (liquid), and changes the chemical composition from gel-based to water-based acid dye. This parameter change eliminates the need for excessive colorants and gels, thereby reducing water consumption and energy usage for washing while still achieving effective color imaging on fibrous flooring materials
Solution Approach 2:
The patent replaces the mechanical jetting/discharging system with a digital printing system that uses piezoelectric or thermal drop-on-demand technology. This substitution allows for precise control of ink deposition, reducing waste of colorants and eliminating the need for excessive washing, thereby reducing both water consumption and energy usage
2Quantity of substance
If high viscosity paste is used for mechanical jetting or discharging, then color imaging can be achieved on fibrous flooring materials, but printing resolution is limited to less than 100 DPI
Solution Approach 1:
The patent changes the viscosity parameter of the ink from high to low, and changes the delivery mechanism from mechanical jetting to digital drop-on-demand printing. This parameter change enables much finer control over ink droplet placement and size, achieving printing resolutions significantly higher than 100 DPI while using precise amounts of colorants without waste
3Quantity of substance
If high viscosity paste with excessive colorants is used, then color imaging can be achieved, but chemicals and VOC are released into the environment causing pollution
Solution Approach 1:
The patent changes the chemical composition parameter of the ink from high viscosity paste containing gel and excessive colorants to low viscosity water-based acid dye. This parameter change eliminates the release of harmful chemicals and VOC into the environment, as the acid dye reacts completely with the fiber without leaving residual harmful substances
Solution Approach 2:
The patent converts the potential harm of excessive colorants and chemicals into a benefit by using precise digital dosing of acid dye that reacts completely with the fiber. The water-based formulation ensures that no harmful VOC are released, and the exact-stoichiometry delivery ensures all colorants are utilized, transforming the potential waste problem into an environmentally friendly process
4Quantity of substance
If high viscosity paste is used for mechanical jetting or discharging, then color imaging can be achieved, but heavy machinery is needed for washing process increasing cost
Solution Approach 1:
The patent changes the ink formulation from high viscosity paste requiring heavy washing machinery to low viscosity water-based acid dye that requires minimal or no washing. This parameter change eliminates the need for heavy machinery in the washing process, reducing capital investment and manufacturing costs while using precise amounts of colorants
Solution Approach 2:
The patent replaces the heavy mechanical washing system with a chemical reaction-based coloring process using acid dyes that bond directly to the fiber. This substitution eliminates the need for heavy washing machinery, thereby reducing manufacturing costs and simplifying the production process while maintaining precise control over colorant usage
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 reduces environmental and energy burdens by eliminating the need for washing and using less ink, achieving high-resolution images with reduced water consumption and waste, while providing a cost-effective and efficient process for producing fibrous flooring materials with vivid, permanent colors.
Implementation Method 1
Piezoelectric type of drop-on-demand printing
Implementation Method 2
The process is directed to using low viscosity aqueous acid dye inks onto the fibrous flooring materials. Such materials is capable of reacting with the acid inks, producing permanent and vivid color images
Data Source
AI summary
A method is provided for imaging fibrous polyamide flooring material. Images are formed on fibrous polyamide flooring material having vivid color and color saturations by piezoelectric digital means without going through washing process or discharging hazardous chemicals. The energy-saving and environmentally friendly method can produce high resolution product with durability and longevity.