Silicon-Based Ceramic Ink Composition for Low-TOC Inkjet Printing
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Solution Overview
Problem
Existing ceramic inks for digital printing face challenges in reducing total organic carbon (TOC) emissions, leading to odor and harmful emissions, while maintaining printing efficiency and quality, due to incomplete combustion of organic solvents and rapid drying, which causes nozzle clogging and print head damage.
Innovation Solution
A ceramic ink formulation with a high concentration of organic or inorganic silicon compounds, replacing about 50% of organic components, which upon heating form odorless compounds like SiOx, SiCx, SiNx, and SiBx, significantly reducing TOC emissions and preventing nozzle clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If traditional organic-based ceramic inks are used, then good printing efficiency and quality are achieved, but TOC emissions and odorous emissions increase significantly
Solution Approach 1:
The patent changes the chemical composition parameters of the ink by replacing organic solvents with inorganic silicon-based compounds (such as silicates, silicones, or silicon-containing water-soluble polymers). This substitution fundamentally alters the ink's chemical properties, enabling it to decompose into odorless compounds during firing while maintaining adequate rheological properties for digital printing application.
Solution Approach 2:
The patent creates a composite ink formulation combining inorganic ceramic pigments with inorganic silicon-based binding agents and dispersants. This composite approach integrates multiple inorganic components that work synergistically to provide both printability and low-emission characteristics, eliminating reliance on organic solvents while maintaining functional performance.
2Object-generated harmful factors
If organic components are reduced to lower TOC emissions, then harmful emissions decrease, but ink dryness and nozzle clogging problems worsen
Solution Approach 1:
The patent introduces inorganic silicon-based compounds as intermediary substances that replace organic solvents. These silicon-based intermediaries serve dual functions: they provide the liquid vehicle necessary for ink flow and print head operation, while simultaneously decomposing into volatile silicon oxides during firing that do not contribute to odorous emissions or TOC levels.
Solution Approach 2:
The patent creates an inorganic-based ink environment using silicon-containing compounds that are chemically inert during storage and application but decompose cleanly during firing. This inorganic environment prevents the formation of harmful organic emissions while maintaining ink stability and preventing premature drying that would cause nozzle clogging.
3Object-generated harmful factors
If inorganic silicon compounds are used to replace organic components, then TOC emissions are reduced below 50 mg/Nm³, but the ink formulation complexity increases
Solution Approach 1:
The patent employs inorganic silicon-based compounds that perform multiple functions simultaneously: they act as binding agents, dispersants, and emission-reducing agents. This multi-functionality simplifies the overall formulation by eliminating the need for separate organic solvent systems, organic dispersants, and emission control additives, thereby reducing formulation complexity despite the inorganic nature of the components.
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
The ink achieves TOC emissions below 50 mg/Nm^3, reducing odorous emissions by 10-60% and preventing print head wear, ensuring high printing efficiency and quality.
Implementation Method 1
which upon heating form odorless compounds like SiOx, SiCx, SiNx, and SiBx, significantly reducing TOC emissions
Implementation Method 2
the combustion of the organic emissions is never complete due to the countercurrent operation of the ceramic kilns
Implementation Method 3
the organic substances that decompose and evaporate during preheating, mixing with the manufactured articles of combustion, are dragged by the gaseous flow towards the kiln's emission stack
Data Source
AI summary
The ceramic ink for digital printing, preferably for inkjet printing, comprises: - at least one solid part comprising at least one ceramic pigment or dye; and - at least one liquid part into which said ceramic pigment or dye is dispersed and comprising one or more vehicles and/or one or more dispersants; wherein at least one of either the one or more vehicles or the one or more dispersants comprises one or more organic or inorganic silicon compounds.