Digital Imaging of Polyamide Flooring With Wash-Free Piezo Inkjet
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Solution Overview
Problem
Current methods for coloring and imaging fibrous flooring materials, such as wet dyeing and mechanical jetting techniques, result in high energy consumption, water waste, and low printing resolution, failing to effectively address environmental and energy burdens while meeting high-quality image requirements.
Innovation Solution
The use of low viscosity aqueous acid dyes in a digital printing process with piezoelectric drop-on-demand technology, which eliminates the need for washing and allows for high-resolution, vivid color imaging on fibrous flooring materials without excessive colorants or energy usage, utilizing a belt feed mechanism and steaming for curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical jetting techniques with high viscosity inks are used, then color imaging can be achieved on fibrous flooring materials, but printing resolution is low (less than 100 DPI) and excessive water and energy are required for washing
Solution Approach 1:
The patent changes the viscosity parameter of the ink from high (mechanical jetting) to low (aqueous-based inkjet ink), enabling the use of digital inkjet printing technology which achieves high printing resolution while eliminating the need for washing processes that consume excessive water
Solution Approach 2:
The patent replaces mechanical jetting techniques with digital inkjet printing technology, substituting a mechanically complex system with a digitally controlled system that uses piezoelectric or thermal actuators to precisely deposit ink droplets, achieving superior resolution without mechanical wear or clogging issues
2Manufacturing precision
If high viscosity paste oversaturated dyeing is used, then color imaging can be achieved, but excessive chemicals and VOC are released into the environment
Solution Approach 1:
The patent changes the chemical composition parameters of the ink from high viscosity paste with excessive colorants and gels to low viscosity aqueous-based ink with precise colorant concentration, eliminating the need for oversaturation and subsequent washing that releases harmful chemicals
Solution Approach 2:
The patent extracts and eliminates the harmful components (excessive colorants, gels, and washing requirements) from the traditional mechanical jetting process, retaining only the essential function of color deposition through a cleaner, more environmentally friendly digital inkjet printing process
3Adaptability or versatility
If screen printing with multiple colors is used, then various color patterns can be produced, but preparation time is long and short run cost is high
Solution Approach 1:
The patent uses digital inkjet printing technology that can directly copy any color pattern from digital files without requiring physical screen templates, enabling rapid production of various color patterns with no preparation time and low cost for short runs
Solution Approach 2:
The patent implements a dynamic, digitally controllable printing system that can rapidly switch between different color patterns by changing digital input files, unlike static screen printing setups that require time-consuming screen preparation and cannot be easily reconfigured
4Manufacturing precision
If mechanical jetting techniques are used, then color imaging can be achieved, but fixing or curing energy needs are excessive
Solution Approach 1:
The patent changes the ink formulation from high viscosity paste requiring intensive curing to low viscosity aqueous-based ink that cures more efficiently through natural evaporation or mild heat treatment, reducing energy consumption while maintaining color fastness
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 high-resolution, energy-efficient, and cost-effective color imaging for fibrous flooring materials, reducing environmental impact by eliminating the need for washing and minimizing chemical waste, while enabling full-color photographic images with improved printing resolution.
Implementation Method 1
Piezoelectric type of drop-on-demand printing
Implementation Method 2
curing the flooring material, with aid of a steamer, by steaming the flooring material
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.