Powder Pattern Formation via Segmented Particle Application
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Solution Overview
Problem
In digital printing, the limited ink and recording medium options for thick film printing restrict the ability to form patterns with high resolution and large film thickness, leading to decreased productivity due to the need for repeated lamination of small-diameter particles.
Innovation Solution
A method involving the sequential application of powders with different particle diameters, where larger particles are applied first and then smaller particles penetrate into the gaps to increase film thickness without compromising resolution, using a laminate-shaping apparatus to form a pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If large-diameter powder particles are used to increase film thickness, then the film thickness increases, but the resolution of the pattern decreases
Solution Approach 1:
The invention divides the powder application process into multiple stages with different particle sizes. Large-diameter particles (first powder) are applied first to form the base structure and provide thickness, while small-diameter particles (second powder) are applied subsequently to fill gaps and refine the pattern. This segmentation allows simultaneous achievement of both thickness and resolution that cannot be obtained with a single particle size.
2Manufacturing precision
If small-diameter powder particles are used to maintain high resolution, then the resolution improves, but the film thickness decreases
Solution Approach 1:
The invention segments the powder particles into two size categories applied in sequence. Small-diameter particles (second powder) are used in the later stage to maintain high resolution by filling gaps between larger particles, while the earlier application of large-diameter particles (first powder) provides the necessary film thickness. This sequential segmentation resolves the trade-off between resolution and thickness.
3Volume of moving object
If lamination of multiple patterns is repeated to achieve both high resolution and large film thickness, then both resolution and thickness can be improved, but the productivity decreases
Solution Approach 1:
Instead of repeating the entire lamination process multiple times, the invention segments the powder particles into two sizes and applies them in a single pass. The first powder (large particles) provides thickness in the first application, and the second powder (small particles) refines the resolution in the same process flow. This eliminates the need for multiple lamination iterations, thereby maintaining productivity while achieving both high resolution and large film thickness.
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 allows for the formation of patterns with increased thickness while maintaining high resolution, reducing the number of printing iterations and improving productivity.
Implementation Method 1
a first powder having a first particle diameter is applied to the liquid pattern such that powdery particles of the first powder adhere to the liquid pattern
Data Source
AI summary
The present invention provides a method of forming a pattern that can form a precise pattern on a variety of media by using powders and provides a pattern-producing apparatus.The method of forming a pattern includes providing a liquid pattern on a surface of a medium, applying a powder to the liquid pattern so as to adhere to the liquid pattern, removing the powdery particles of the powder not adhered to the liquid pattern to give a pattern of the powder, and further applying another powder to the pattern of the powder.