Flexible Print Base Layer for High-Definition Printing on Thermoplastic Foils
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Solution Overview
Problem
Existing digital printing technologies face challenges in applying high-quality digital prints on dense and smooth surfaces such as thermoplastic foils used in LVT floors and resin-impregnated papers in laminate floors, as ink drops tend to float and bleed, making it difficult to achieve high-definition images.
Innovation Solution
A method involving a flexible sheet-shaped semi-finished print base with a substrate and a print layer, utilizing ink-receiving particles and a binder and powder (BAP) printing method to apply digital images on dense surfaces, where pigments are bonded with a transparent layer using heat and pressure, ensuring compatibility with production methods and bonding layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If digital printing is applied directly on dense surfaces such as thermoplastic foils or resin-impregnated papers, then the production process is simplified and productivity is improved, but the ink drops float and bleed during printing and pressing, resulting in poor image quality
Solution Approach 1:
The patent introduces a print layer comprising ink-receiving particles as an intermediary between the dense substrate and the digital print. This print layer acts as a mediator that enables ink jet deposition on otherwise unsuitable surfaces, preventing ink float and bleed while maintaining the simplicity and productivity of direct printing processes.
Solution Approach 2:
The patent employs a print layer made of ink-receiving particles that create a porous structure on the dense substrate. This porous layer allows ink drops to be absorbed and held in place, preventing them from floating or bleeding during the printing and pressing operations, thereby achieving high image quality without compromising production efficiency.
2Adaptability or versatility
If digital printing is performed before impregnation on decorative paper, then the digital technology flexibility is utilized, but the ink drops bleed during pressing when the melamine layer becomes liquid
Solution Approach 1:
The patent applies digital printing on the print layer before the lamination and pressing operations. The ink-receiving particles are pre-applied to create a stable base that will hold the ink during subsequent high-temperature and high-pressure processing, ensuring print stability throughout the manufacturing process.
Solution Approach 2:
The porous structure of the ink-receiving particles provides a stable matrix that absorbs and secures the ink drops, preventing them from bleeding during the pressing operation even when the melamine resin becomes liquid. This maintains both digital printing flexibility and print reliability.
3Manufacturing precision
If a print layer with ink-receiving particles is introduced to enable high-quality digital printing, then image quality is improved, but the device complexity and process steps increase
Solution Approach 1:
The patent combines the print layer application with existing lamination processes. The print layer comprising ink-receiving particles is integrated into the decorative layer structure, merging the printing preparation step with the existing material lamination workflow, thereby reducing overall process complexity despite adding functional capability.
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 high-quality digital printing on dense surfaces by preventing ink float and bleed, allowing for strong lamination and maintaining image quality, thus overcoming the limitations of conventional printing methods.
Implementation Method 1
The particles are bonded to said surface
Data Source
Figure 1a~1d
Figure 2a~2d
Figure 3a~3f
AI summary
The disclosure relates to a flexible sheet shaped print base comprising a substrate (4) and a print layer (34). The substrate (4; 4a) has two opposite surfaces, wherein one of the surfaces comprises a thermoplastic material and is essentially covered with the print layer. The print layer comprises particles (31) comprising fibres or a polymer material, wherein the particles are bonded to the surface comprising a thermoplastic material.