Water-Based Ink Pigment Circulation for Digital Printing

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Solution Overview

Problem

Current digital printing technologies for floor surfaces, particularly those with thermosetting resins, face challenges in maintaining image quality due to pigment bleeding and high costs associated with producing stable aqueous pigment dispersions for large-scale production of high-quality wood and stone designs.

Innovation Solution

The use of a water-based ink comprising a pigment mix with larger pigments (200-500 nm) and a wide particle distribution, stabilized through steric stabilization, which can be applied using Piezo print heads with large nozzle openings and an ink circulation system to prevent sedimentation, allowing for cost-effective digital printing on surfaces like wood and stone designs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If small pigments are used in water-based ink for digital printing on thermosetting resin surfaces, then image quality is improved, but production cost increases due to costly milling processes

Engineering Contradiction:

Improveimage qualityVSAvoidproduction cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent changes the pigment particle size parameter from conventional small sizes (requiring costly milling) to larger sizes (200-500 nm) that can be produced more economically while maintaining image quality through optimized ink formulation and print head design

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses larger, less expensive pigments that do not require costly milling processes, accepting that these pigments will settle over time but can be easily re-suspended, replacing the need for expensive stable dispersions

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If stable aqueous pigment dispersions are used for digital printing, then image integrity is maintained under heat and pressure, but production cost increases

Engineering Contradiction:

Improveimage integrityVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive stable pigment dispersions with cheaper ink formulations containing larger pigments that naturally settle but can be easily re-suspended through circulation, achieving similar reliability at lower cost

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The ink circulation system automatically re-suspends settled pigments through continuous movement and agitation, making the system self-maintaining without requiring expensive stabilizing agents or complex formulation

Inventive Principle:

Principle #25Self-service

3Productivity

If ink circulation system is implemented to prevent pigment sedimentation, then printing continuity is improved, but device complexity increases

Engineering Contradiction:

Improveprinting continuityVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent implements a continuous ink circulation system that constantly moves ink through the print head and reservoir, preventing pigment settlement and ensuring uninterrupted printing operations

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The circulation system periodically re-suspends settled pigments and returns them to the ink reservoir, effectively recovering and reusing pigment material that would otherwise be wasted

Inventive Principle:

Principle #34Discarding and recovering

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 enables high-quality digital printing on surfaces with wood or stone designs without the need for costly milling of pigments, maintaining image integrity under heat and pressure, and reducing production costs by using larger pigments that settle slowly, allowing for efficient ink circulation and reuse.

Implementation Method 1

printing by piezo ejection of the water-based ink

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

circulating said water-based ink within said at least one Piezo print head for preventing pigment sedimentation

Methodology Applied

Scientific EffectSedimentation: Sedimentation

Implementation Method 3

providing a steric stabilisation of the pigments

Methodology Applied

Scientific EffectSteric stabilization:

Data Source

PatentEP3099499B1A method of printing a digital image on a substrate attached to a panel and a water-based ink for digital printing on a substrate

Publication Date: 2025.01.01 CERALOC INNOVATION AB

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AI summary

Water-based ink comprising a pigment mix and a method to form a digital print on a substrate with a pigment mix comprising large pigments and a Piezo ink head equipped with an ink circulation system, the method including: providing a water-based ink including an aqueous pigment mix including settling pigments, a binder including an acrylic resin dispersion,and a viscosity increasing substance including glycol and/or glycerine, providing a steric stabilisation of the pigments and adapting the size of the pigments and the viscosity of the water-based ink such that a settling velocity of the pigments exceeds about0.001 mm/min at 25°C, circulating said water-based ink within said at least one Piezo print head, and printing a digital image with said at least one Piezo print head by applying ink drops of said water-based ink on the substrate.