Flatbed printer with integrated creasing and cutting

Abstract

Embodiments of the present invention add cutting tools and creasing wheels to flatbed printers, reducing the number of steps in the workflow, allowing cutting and creasing without image / media realignment, and reducing floor space requirements in smaller factories.

Description

[Technical Field]

[0001] (Related Applications) This application claims priority to U.S. Patent Application No. 18 / 154,738, filed January 13, 2023, the entire text of which is incorporated herein by reference.

[0002] Various embodiments disclosed herein relate to an integrated creasing and cutting flatbed printer. [Background technology]

[0003] Conventional printers use post-processing media-cutting machines, such as analog die-cutting machines or dedicated digital cutters, to cut the printed media into the desired shape, such as a flat cardboard box. Media-cutting systems are available from manufacturers such as Kongsberg Precision Cutting Systems and Zund Systemtechnik AG.

[0004] Conventional printers also use in-line media folding / creasing machines, available from manufacturers such as Horizon, Inc. and Morgana Systems.

[0005] Machines that both cut and crease media are also known, such as those manufactured by Inline Finishing System / Digital Finishing Group.

[0006] Currently, all such cutting and creasing operations are performed in a separate machine after the media is printed. Moving the printed media from the printer to such a cutting and creasing machine introduces registration problems and reduces the quality of the finished product. Also, such cutting and creasing machines slow down the processing of media due to the processing delays caused by the additional step of transporting the media from the printer to the cutting and / or creasing machine and aligning it before further processing. Furthermore, such machines are large and take up a significant amount of space in a media manufacturing facility. Summary of the Invention

[0007] Embodiments of the present invention allow for the elimination of secondary processing machinery such as cutting and creasing machines by adding cutting tools and creasing wheels to a flatbed printer, allowing printing and finishing to occur in one operation. This reduces the number of steps in the workflow, allows cutting and creasing without image / media realignment, and reduces floor space requirements in small work bays. Laser [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a perspective view of an integrated creasing and cutting flatbed printer according to one embodiment of the present invention; [Figure 2] 2 is a side view of the flatbed printer of FIG. 1 according to one embodiment of the present invention. [Figure 3] 10 illustrates a user dashboard dialog for setting printing parameters, including access to a media database, according to one embodiment of the present invention. [Figure 4] 4 illustrates a user dashboard dialog for setting printing parameters within the media database of FIG. 3 according to one embodiment of the present invention. [Figure 5] FIG. 2 is a top view of a printer showing media alignment pins, according to one embodiment of the present invention. [Figure 6] A side view of the printer showing the UV LED cover hiding the CO2 laser head behind the printer carriage. [Figure 7] FIG. 1 is a side view of a printer showing a CO2 laser on a printer carriage according to one embodiment of the present invention. [Figure 8] FIG. 1 is a rear view of a printer showing the CO2 laser on-beam according to one embodiment of the present invention. [Figure 9] 1 is a side view of a conventional printer showing an integrated creasing and cutting tool. [Figure 10] FIG. 2 is a detailed view of a cutting tool according to one embodiment of the present invention. [Figure 11] 1A-D are detailed views of various creasing tools according to one embodiment of the present invention. [Figure 12] FIG. 2 is a top view of a printer showing XY carriage and gantry motion vectors according to one embodiment of the present invention. [Figure 13] FIG. 2 is a top view of a printer illustrating angular carriage and gantry motion vectors according to one embodiment of the present invention. [Figure 14] 1A and 1B show a creasing module (A, B) mounted on a printer carriage according to one embodiment of the present invention. [Figure 15] FIG. 2 is a plan view of media processed using the integrated creasing and cutting flatbed printer disclosed herein. DETAILED DESCRIPTION OF THE INVENTION

[0009] FIG. 1 is a perspective view of an integrated creasing and cutting flatbed printer according to one embodiment of the present invention. In FIG. 1, printer 100 includes a carriage 102 and a gantry 103, which cooperatively move a printhead assembly 104 and UV curing lamps mounted within a side cover of a laser 106 in X and Y directions above a print bed 108 to process print media (not shown). The print media is placed on the print bed and aligned with pins 110 on the print bed to align the media with the head assembly and ensure accurate printing. In other embodiments of the invention, alignment can be achieved by placing alignment bars on one or more edges of the print bed, by using an imaging system that images the position of the media on the print bed and adjusts the amount of gantry and carriage movement, or by using a vacuum-assisted retention mechanism.

[0010] In an embodiment of the present invention, a flatbed printer can be equipped with a cutting laser 106 and a creasing wheel, thereby eliminating the need for secondary processing machinery such as cutting and creasing machinery. In an embodiment of the present invention, the cutting laser is a diode laser module. In an embodiment of the present invention, the printer can include both a cutting device and a creasing device, or only one of the cutting device or the creasing device.

[0011] In an embodiment, the laser is used to cut simple shapes, and the creasing wheel adds creases to the media for folding. This reduces the number of steps in the workflow, allows cutting and creasing without image / media realignment, and reduces the floor space required in the production facility by eliminating the need for additional machinery for post-processing. An exhaust 107 is provided to vent exhaust gases from the printer as the laser cuts the media.

[0012] FIG. 2 is a side view of the flatbed printer of FIG. 1 according to an embodiment of the present invention. An embodiment of the present invention can eliminate the need for secondary processing machinery, such as cutting and creasing machines. In FIG. 2, the head assembly 104 includes a cutting tool 204 and a creasing wheel in addition to the printhead. An umbilical cable 205 connects the printhead and cutting tool components to the printer for power and data transfer. In an embodiment of the present invention, the printer allows for in-situ cutting and creasing. A typical printer has a cutting speed of approximately 4 ips, but this can be varied depending on the application. For example, thinner materials can be cut at faster speeds. The creasing speed is approximately 54 / 20 ips at 0.5 g acceleration, but this can also be varied depending on the application. For example, different folds and materials require different pressures. Also, faster or slower speeds are acceptable.

[0013] Embodiments of the invention cut and crease in straight lines and at various angles, such as 45 degrees. Other embodiments can cut complex shapes. Additionally, complex creases can be created depending on the creasing tool used. Cutting parameters (e.g., laser power level and shape) and creasing parameters (e.g., pressure and speed) can be set through the user dashboard dialog when setting print parameters.

[0014] FIG. 3 illustrates a user dashboard dialog for setting print parameters, including access to a media database, according to one embodiment of the present invention. FIG. 4 illustrates a user dashboard dialog for setting print parameters within the media database of FIG. 3, according to one embodiment of the present invention. In this embodiment of the present invention, the crease pressure is set by an air pressure regulator on the printer's air pressure panel. This pressure is typically set each time the crease wheel type is changed. The UI enables the cut function ("Cut Fold" in FIG. 3). The laser cut intensity and cut speed are media dependent and are set within the printer's media database (see FIG. 4). One embodiment uses manual laser intensity and regulators, i.e., a fixed cut speed using two physical knobs on the printer.

[0015] In embodiments of the invention, the printed media shape can be set simultaneously by entering print parameters and image information into the printer controller. Paths (folding and cutting) are drawn in Adobe ILLustrator, Adobe Photoshop, or a similar application. EFI Fiery XF, a RIP (raster image processor), converts PDF files into printable raster images with embedded cutting / folding instructions.

[0016] Once printing is complete, the gantry and carriage move to perform cutting and creasing based on instructions embedded in the current image. Because the print table is always perfectly aligned with the media, the image can be instantly creasing and cut. This reduces the number of steps in the workflow, allows cutting and creasing without image / media realignment, and reduces the floor space required in the production facility.

[0017] 5 is a top view of a printer showing media alignment pins 110 according to one embodiment of the present invention. In embodiments of the present invention, alignment bars can be used to align the media.

[0018] Figure 6 is a side view of the printer showing the UV LED cover concealing the CO2 laser head 602 on the back of the printer carriage. Figure 4 shows the CO2 laser head mirror and lens assembly 402. In this embodiment of the invention, the CO2 laser provides higher cutting power, allowing for faster cutting, but it also has drawbacks. It is a large glass tube, so liquid cooling (water circulation) is required. Also, the beam is invisible, which can make it difficult to work with.

[0019] FIG. 7 is a side view of a printer showing a CO2 laser 704 on a printer carriage according to one embodiment of the present invention. An alternative embodiment of the present invention uses a diode laser with sufficient power to cut the target material but not enough power to cut through a metal (aluminum) print table. Target media can include any of the following: paper, cardboard, corrugated board, PSA / film, fabric, acrylic, expanded PVC, wood, polystyrene, etc. Some materials, such as corrugated plastic with an internal structure and a heat-sensitive surface (e.g., Coroplast), can be cut with multiple passes of the laser. Coordinated axis movement of the carriage and gantry enables cutting of curves and circles. CO2 lasers are larger, more powerful laser tubes than diode laser modules, which require liquid cooling and are generally more difficult to manage (e.g., more complex power supplies). Laser diodes are self-contained, easy to use, and solid-state devices (similar to LEDs) that are easier to use than CO2 lasers. Neither laser has enough power to cut through a print table.

[0020] In an embodiment of the invention, the laser power is adjustable in an analog fashion (0-100%). This allows the cutting power to be set to match the media being cut. The laser power adjustment signal can be provided to the printer along with the imaging, cutting, and creasing instructions, or can be set independently.

[0021] The laser assembly may be equipped with a flame detector to ensure there is no flame when the laser is shut off. The gantry may be equipped with an exhaust mechanism to remove smoke as the cut is being made. In an embodiment of the invention, the laser assembly is equipped with a complete air exhaust mechanism with fans and filters.

[0022] In embodiments of the present invention, the laser cutting head may be replaced by a knife or other cutting tool.

[0023] In an embodiment of the present invention, a CNC-type router spindle can be used in place of a laser cutting head to cut hard materials such as aluminum composites (Diebond) or thermal media (FOME-COR). For example, foam core material has a hard outer surface and a soft inner core. A router spindle for such materials is preferably long enough to cut through the hard outer layer of the material and has a shape that allows it to inscribe grooves in the soft inner core at 45 degrees or other angles and fold the material at 90 degrees or other angles. The spindle can utilize a laser air bleed function and a carriage lift system with high-precision height setting (<0.005 inches).

[0024] Figure 8 is a rear view of a printer showing a CO2 laser beam according to one embodiment of the present invention. In Figure 8, a CO2 laser tube 702 sends a beam to a mirror and lens assembly 402, where the beam is focused onto the substrate to be cut.

[0025] FIG. 9 is a side view of a conventional printer showing an integrated creasing and cutting tool. In FIG. 9, head assembly 900 includes creasing wheel 902. The printer in FIG. 9 is a conventional dedicated (Kongsberg) cutting / creasing machine. An alignment camera 904 is required to realign the printed media for cutting. This step is not necessary in the present invention. A knife blade 906 is used to cut the media. This knife configuration requires that the table surface 908 be a cutting mat. In the present invention, a cutting mat is not required because a laser is used.

[0026] FIG. 10 is a detailed view of a cutting tool 204 according to another embodiment of the present invention.

[0027] 11A-11D are detailed views of various creasing tools according to one embodiment of the present invention. For example, end views are shown illustrating a thin crease line 202a (FIG. 11A), a thick crease line 202b (FIG. 11B), and a double crease line 202c (FIG. 9C). Also shown in FIG. 11D is a side view of an exemplary crease wheel 202d. Those skilled in the art will understand that any desired crease line can be provided.

[0028] In embodiments, the creasing wheels are pneumatically driven, but could also be solenoid-driven (electronic). The creasing wheels rotate relative to the carriage so that they always point in the direction of travel (or at an angle if the X- and Y-axis movements are synchronized). In embodiments of the invention, the creasing wheels are removable and can be replaced with different sizes / profiles. The creasing wheels can also be replaced with knives or other cutting tools. The gantry / carriage speed is adjustable (ips), and the creasing pressure is also adjustable (psi).

[0029] Figure 12 is a top view of a printer according to one embodiment of the present invention and shows the XY motion vectors of the carriage and gantry. Figure 13 shows the angular motion vectors of the carriage and gantry according to one embodiment of the present invention. Figure 12 shows a flatbed printer with two axes of motion that work together as a Cartesian coordinate system or XY print bed 108. These axes of motion consist of the X axis 122 along which the carriage 102 moves on the gantry 103, and the Y axis 120 along which the gantry moves. The carriage can be positioned anywhere above the print bed.

[0030] As shown in Figure 13, by moving both axes simultaneously through the coordinated movement of the gantry movement 133 and the carriage movement 134, the carriage can be moved through an angle of 130 degrees. Although this is not normally used during printing, the table can be moved through an angle of 130 degrees. By moving the two axes at different speeds (or directions), any angle can be achieved.

[0031] To rotate, the creasing wheels must be oriented in the direction of travel. This can be achieved by attaching the wheels to casters, which use the force of the motion to make the wheels follow the movement of the carriage. This makes the starting position of the crease less predictable. In one embodiment of the present invention, a motor (see Figures 14A and 14B) is used to rotate the wheels to match the direction of travel before stretching them onto the media.

[0032] Figures 14A and 14B show a creasing module 140 (144) mounted on a printer carriage in accordance with one embodiment of the present invention. An embodiment of the creasing module is pneumatically driven. In other embodiments, the creasing module can be actuated via springs or electric solenoids. Figure 14A shows the creasing module in an extended position, while Figure 14B shows the creasing module in a retracted position. Air pressure supplied to one or more pneumatic cylinders 148 lifts the creasing wheel 146 off the media. This pressure is reversed and used to extend the creasing wheel down into the media. This pressure is adjustable to accommodate various media and creasing wheel geometries. The system provides instructions, embedded with print imaging data, to print workflow software for extending and retracting the creasing wheel and for setting the pressure on the creasing wheel. In an embodiment of the present invention, a motor 142 is provided to rotate the creasing wheel in response to position instructions received from the printer control system.

[0033] The printer carriage of an exemplary printer is moderate in weight (e.g., on the order of 100 pounds). A gantry beam and lift system supports the creasing wheel and, in embodiments, can be repeatedly positioned with an accuracy of 0.001 inch. This robustness allows the creasing wheel to easily accommodate the force (approximately 10 pounds) exerted on the media. Unlike the laser, the creasing module's large size typically requires it to be mounted outside the carriage (an optional component), behind the head assembly 104, UV curing lamps, and laser 106, within its side cover. This requires a subframe with sufficient strength to transfer the weight and force back to the main carriage plate.

[0034] Figure 15 is a top view of media processed using the integrated creasing and cutting flatbed printer disclosed herein. The various creases 1001 and cuts 1002 shown in Figure 15 were made by the printer as the media was printed.

[0035] The terminology used herein has been selected primarily for ease of reading and explanation purposes. It has not been selected to limit or restrict the subject matter. Accordingly, it is intended that the scope of the present technology be limited not by the detailed description of the invention, but by the claims of this application issued based thereon. Accordingly, the disclosure of various embodiments is intended to illustrate, but not limit, the scope of the present technology, which is set forth in the following claims.

Claims

1. Print bed; a gantry configured to traverse the print bed in a back-and-forth direction; a carriage secured to the gantry and configured to traverse laterally across the print bed; and at least one inkjet; a cutting device; and Creasing device a print head fixed to the carriage; A flatbed printer comprising: the gantry and carriage effecting coordinated movement of the print head relative to media registered on the print bed and sequential operation of the at least one inkjet, the cutting device, and the creasing device to print an image on the media, cut a pattern in the media, and creasing the media while the media is secured on the print bed; Flatbed printer.

2. one or more pins disposed on the print bed for aligning the media with the head assembly for accurate printing, cutting, and creasing; The flatbed printer according to claim 1 .

3. further comprising alignment bars located on one or more edges of the print bed for aligning the media with the head assembly for accurate printing, cutting, and creasing; The flatbed printer according to claim 1 .

4. an imaging system configured to capture the position of the media on the print bed and to coordinate the movement of the gantry and carriage to align the media with the head assembly for accurate printing, cutting, and creasing; The flatbed printer according to claim 1 .

5. a vacuum-assisted retention mechanism configured to secure the media on the print bed during printing, cutting, and creasing; The flatbed printer according to claim 1 .

6. the cutting device further comprises a laser, a diode laser, a CO2 laser, or a CNC router spindle; The flatbed printer according to claim 1 .

7. The printer further includes an exhaust that exhausts smoke generated when the laser cuts the media. The flatbed printer according to claim 1 .

8. The cutting speed and / or pressure are selectively variable; The flatbed printer according to claim 1 .

9. The creasing speed and / or pressure are selectively variable; The flatbed printer according to claim 1 .

10. and a user dashboard for setting cutting and creasing parameters when setting the printing parameters. The flatbed printer according to claim 1 .

11. Once printing on the media is complete, the printer cuts and creases the media based on instructions embedded in the printing information for the current image. The flatbed printer according to claim 1 .

12. The media comprises any of paper, cardboard, corrugated board, paperboard, PSA / film, fabric, acrylic, expanded PVC, wood, polystyrene, aluminum composite (Diebond), and thermal media (FORME-COR); The flatbed printer according to claim 1 .

13. Coordinated movement of the carriage and gantry axes is performed for cutting curves and circles. The flatbed printer according to claim 1 .

14. The power output of the cutting device is adjustable; The flatbed printer according to claim 1 .

15. a cutting device power regulation signal is provided to said printer along with imaging, cutting, and creasing instructions; 15. The flatbed printer of claim 14.

16. the cutting device further comprising a flame detector for verifying that no flame is present after the cutting device has been stopped; The flatbed printer according to claim 1 .

17. The printer can be configured to temporarily accept any of a plurality of creasing devices; The flatbed printer according to claim 1 .

18. the creasing device is configured to create either a thin crease line, a thick crease line, or a double crease line; 18. The flatbed printer of claim 17.

19. The creasing device is either pneumatic or electric. The flatbed printer according to claim 1 .

20. the creasing device being rotatably operable to maintain alignment with the direction of movement of the gantry and the carriage; The flatbed printer according to claim 1 .

21. the creasing device comprises a knife or other cutting tool; The flatbed printer according to claim 1 .

22. Print bed; a gantry configured to traverse the print bed in a back-and-forth direction; a carriage secured to the gantry and configured to traverse laterally across the print bed; and at least one inkjet; and cutting devices; a print head fixed to the carriage; A flatbed printer comprising: the gantry and carriage effecting coordinated movement of the print head relative to media registered on the print bed and sequential operation of the at least one inkjet, the cutting device, and the creasing device to print an image on the media, cut a pattern in the media, and creasing the media while the media is secured on the print bed; Flatbed printer.

23. Print bed; a gantry configured to traverse the print bed in a back-and-forth direction; a carriage secured to the gantry and configured to traverse laterally across the print bed; and at least one inkjet; and creasing devices; a print head fixed to the carriage; A flatbed printer comprising: the gantry and carriage effecting coordinated movement of the print head relative to media registered on the print bed and sequential operation of the at least one inkjet, the cutting device, and the creasing device to print an image on the media, cut a pattern in the media, and creasing the media while the media is secured on the print bed; Flatbed printer.

24. Print bed; Gantry; a carriage fixed to said gantry; the printhead fixed to the carriage, the printhead including at least one inkjet; a cutting device; and Creasing device providing a printer comprising: traversing the print bed back and forth using the gantry; using the carriage to traverse the print bed in a left-right direction; manipulating the gantry and carriage to effect coordinated movement of the printhead relative to media positioned on the print bed; sequentially operating the at least one inkjet, the cutting device, and the creasing device while the media is stationary on the print bed; printing an image onto the media with the at least one inkjet; said cutting device cutting a pattern in said media; and The creasing device creasing the medium. A method for providing the above.

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