Single-pass inkjet printer for Z-fold (fanfold) materials

Abstract

Embodiments of the present invention use an inkjet printing system, which is a non-contact printing system, to continuously print on Z-fold material without image quality defects. The Z-fold material is first created as a base material, and then printed (decorated). In embodiments of the present invention, printing is performed on a flat sheet-like material that has been Z-folded, and then the box is formed by cutting, folding, bonding, etc. Therefore, boxes manufactured using the present invention can be printed on the entire surface of the box, rather than being printed after the box is formed. When printing is done after the box is formed, the decoration is limited to one area / surface of the box.

Description

Technical Field

[0001] (Related Application) This application claims the priority of U.S. Patent Application No. 18 / 188,383, filed on March 22, 2023, the entire content of which is incorporated herein by reference.

[0002] The various embodiments disclosed herein relate to single-pass inkjet printers for Z-fold (fan-fold) materials.

Background Art

[0003] Currently, the decoration of Z-fold (fan-fold) materials is performed on a corrugated manufacturing machine or roll-to-roll before or during the formation of the Z-fold. This is often referred to as pre-printing. This pre-printing can be achieved by analog printing techniques such as gravure printing or flexographic printing. It can also be achieved by roll-to-roll inkjet printing, in which case the printed material is placed on a corrugated manufacturing machine and the Z-fold is formed. Since such pre-printing is performed in an upstream process of the box forming process, true on-demand printing production cannot be realized. Rather, the printing is limited to repetitive patterns. Companies such as CMC (https: / / www.cmcmachinery.com / ?page_id=3304) offer machines that decorate boxes before the cutting, folding, and gluing processes, but with such machines, it is not possible to decorate the boxes on demand or adjust the printing design for 1:1 printing or a design impactful to the end customer / product. There are also companies that perform decoration after the box is formed and fully assembled, but the range of the surface to be decorated is limited to the upper surface of the box.

[0004] Currently, inkjet printers can print roll-to-roll or sheet-to-sheet, but it is not currently possible to print Z-fold material on a flat surface at the box-forming stage. Z-fold corrugated cardboard is a continuous sheet of corrugated cardboard that is accordion-folded to maintain a connected state within an infinite framework. Available in various types and sizes, Z-fold sheets are an ideal solution for businesses that need appropriately sized boxes, as they eliminate the need for overpackaging and reduce corrugated cardboard waste. However, there is no system that can provide fully digital printing at the box creation and shipping stages. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] U.S. Patent No. 11,407,238 [Patent Document 2] U.S. Patent No. 10,913,294 [Overview of the project]

[0006] Due to the problems associated with the folds in Z-fold materials, current decorative workflows involve printing using pre-printing techniques before creating the folds. In embodiments of the present invention, inkjet printing is employed. Since inkjet printing is a non-contact printing system, in embodiments of the present invention, continuous printing is performed on the Z-fold material without causing image quality defects. Therefore, this workflow differs from the conventional method of first creating the Z-fold material and then printing (decorating) it. In embodiments of the present invention, printing is performed on a flat sheet of Z-fold material, and then the box is formed by die-cutting, folding, bonding, etc. Therefore, since the box manufactured using the present invention is not printed after the box is formed, it is possible to print on the entire box. When printing is performed after the box is formed, the decoration is limited to one area / surface of the box. [Brief explanation of the drawing]

[0007] [Figure 1] This document shows a single-pass inkjet printer for Z-fold (fanfold) materials according to one embodiment of the present invention. [Figure 2] This shows a Z-fold material supply source integrated with a single-pass inkjet printer for Z-fold (fanfold) materials according to one embodiment of the present invention. [Figure 3] This shows how Z-fold material is supplied to a single-pass inkjet printer for Z-fold (fanfold) material according to one embodiment of the present invention. [Figure 4] This shows a printed Z-fold material discharged from a single-pass inkjet printer for Z-fold (fanfold) material according to one embodiment of the present invention. [Figure 5] This shows how a pre-printed Z-fold material is supplied to a cutting tool according to one embodiment of the present invention. [Figure 6] This shows how a printed, folded, and glued box is ejected from a folding and gluing tool according to one embodiment of the present invention. [Figure 7] Figures 7A to 7C show a sheet planarity detection system according to one embodiment of the present invention. [Figure 8] This is a block diagram of the system architecture according to the present invention. [Figure 9] A block diagram showing an example of a processing system capable of performing at least some of the operations described herein. [Modes for carrying out the invention]

[0008] Embodiments of the present invention use an inkjet printing system, which is a non-contact printing system, to perform continuous printing on Z-fold material without image quality defects. This makes it possible to print instantly from a Z-fold web without waiting for setup, plates, or die-cutting. Thus, first the Z-fold material is created, and then the material is printed (decorated). Embodiments of the present invention print on a flat sheet of Z-fold material before the box is formed by die-cutting, folding, bonding, or any other method. Thus, boxes manufactured using the present invention can be printed on the entire surface of the box, rather than being printed after the box is formed. If printed after the box is formed, the decoration is limited to one area / surface of the box.

[0009] Figure 1 shows a single-pass inkjet printer 10 for Z-fold (fanfold) material. One embodiment of the present invention will be described. In Figure 1, the printer 10 includes a feeder 12 that supplies a continuous web of Z-fold sheet material to a cutting machine 14. The cutting machine cuts the sheet to the desired length to fit a box of a specific size to be manufactured. The length of the sheet defines the outer circumference of the box manufactured by the printer, and the width of the sheet defines the height of the box manufactured by the printer.

[0010] The cut sheet is sent to a single-pass inkjet printer 16. The image of the entire box to be formed is printed onto the sheet. Next, the sheet is sent to a die-cutting, folding, and gluing machine 18, where the sheet is cut along the contour of the desired box while the box is flat and before folding and gluing. Next, the die-cut sheet is folded and glued to complete the box.

[0011] A key feature of this invention is that the printing press is programmable. The feeder, cutting machine, inkjet printer, and the die-cutting, folding, and gluing elements of the entire printing press are coordinately controlled by the processor 19. The processor can be programmed to feed Z-fold material along the printing press path, cut the Z-fold material to a predetermined length, image the cut material, and then die-cut, fold, and glue the imaged sheet to form a box. Uniquely, the entire box manufacturing process is performed as a single, continuous set of operations, allowing for the production of any number of boxes of any shape and design on demand. Thus, the processor provides control signals to each element of the box manufacturing workflow and receives status signals from each element of the box manufacturing workflow to ensure that each element of the workflow functions in coordination with the other elements of the workflow.

[0012] Images can be resized in real time to match the size of the boxes being manufactured. For example, a fulfillment center might be packing orders of tennis shoes and water bottles. The system determines the size of the boxes needed to pack the orders in real time, sends the Z-fold material to the cutting machine, and the cutting machine then cuts the Z-fold material into sheets of the appropriate size. In this example, the required box size may differ for each order. Therefore, the printing press cuts the sheets to the appropriate length for each different box size.

[0013] An order for tennis shoes and water bottles is related to sporting goods, but the next order to be packed might be for books and music. Therefore, the processing system controls the inkjet printer to print different images on each box so that the images are appropriate for the contents of the box. For example, the box for tennis shoes and water bottles might depict a sporting scene, while the box for books and music might depict a music concert or a scene from one of the books included in the order.

[0014] The processing unit can add targeted advertisements personalized for the recipient based on, for example, the recipient's profile to the image printed on the box and that also match the contents of the box. For example, an order for tennis shoes and a water bottle may include a promotion for a sports drink based on the type of products packed in the box and the recipient's past purchase history.

[0015] Next, the processing unit operates the printing machine to perform die-cutting, folding, and gluing of the box. In this way, a custom box is created on demand for each order. The die-cutting may change not only the size of the boxes to be manufactured but also the features of the boxes. For example, scalloped edges or cut lines may be provided on the edges of the box so that the box can be easily opened.

[0016] In other embodiments, a series of boxes with different sizes and different images may be manufactured. For example, a manufacturer may want to package 100 sets of headphones, 50 amplifiers, and 250 rolls of cables. The processing system is programmed to apply a design suitable for the products to be stored to each box and manufacture the required number of the desired boxes for these products.

[0017] FIG. 2 shows a Z-fold material supply source 12 arranged parallel to a single-pass inkjet printer for Z-fold (fan-fold) materials according to an embodiment of the present invention. In the example of FIG. 2, a plurality of Z-fold material supply sources 20, 22 are shown.

[0018] FIG. 3 shows a state in which Z-fold materials are supplied to a single-pass inkjet printer for Z-fold (fan-fold) materials according to an embodiment of the present invention. As shown in FIG. 3, the Z-fold material is cut into sheets 30 of a desired length by a cutting machine 14. Existing supply and cutting machines may be adapted for the supply and cutting of Z-fold materials in embodiments of the present invention.

[0019] Figure 4 shows a printed Z-fold material discharged from a single-pass inkjet printer for Z-fold (fan-fold) materials according to an embodiment of the present invention. In Figure 4, an inkjet printer 16 prints an image on a cut sheet 40. The printed cut sheet is sent along a print path to a die-cutting, folding, and gluing machine 18. An exemplary die-cutting, folding, and gluing machine is manufactured by Highcon (https: / / www.highcon.net / ).

[0020] Figure 5 shows how a printed Z-fold material is sent to a folding, cutting, and gluing machine according to an embodiment of the present invention. Figure 5 shows how the printed cut sheet 40 is sent along a print path to a die-cutting, folding, and gluing machine 18.

[0021] Figure 6 shows a printed, folded, and glued box 60 discharged from a folding and gluing tool according to an embodiment of the present invention. This printer provides real-time on-demand box manufacturing that integrates all steps of box manufacturing into a single workflow. Each box in a series of boxes is custom cut, printed, die cut, folded, and glued. Flatness detection

[0022] Z-fold sheets are not flat at the fold points. Rather, the sheet is curved at the fold. Since the printing press cuts sheets of varying lengths from the Z-fold material web according to the specifications of the box being manufactured, some sheets may not have folds, some may have folds near the center of the sheet, and others may have folds near the edges of the sheet. A standard inkjet printer would not be able to print faithfully because, as the sheet moves along the print path, the curvature of the sheet caused by the folds changes the distance from the inkjet printhead to the sheet. Due to the nature of the Z-fold material, this curvature may appear as concave or convex areas. This is because the Z-fold web has alternating folds. When the sheet curves at the folds, there is a risk that the curved portion of the sheet will collide with the delicate and expensive printhead, potentially damaging the printing press. Embodiments of the present invention provide an inkjet printer that addresses this problem by generating a strong vacuum on the print bed and firmly pulling the sheet downwards to align it planely with the printhead.

[0023] In embodiments of the present invention, the vacuum suction force can achieve a holding force of 2000g, for example, compared to 300g commonly used in HP printers. This level of vacuum suction allows the printer to flatten Z-fold material. In embodiments of the present invention, the vacuum suction force is adjustable. The pressure setting is fixed, for example, 500g. The system controls the blower of the vacuum source to adjust the vacuum suction force to the set value according to the quality of the material to be printed. Sensors detect the warping of each sheet printed by the printer and provide instructions to the printer operator as needed to increase the vacuum suction force in response to warping, warping, or defects in the sheet. Furthermore, the system can reduce artifacts and improve image quality by adjusting the area of ​​the vacuum system to match the material to be printed (see Patent Document 1) and controlling the air below the system (see Patent Document 2).

[0024] Figures 7A-7C illustrate the sheet flatness detection system according to the present invention. As shown in Figures 7A-7C, a strong vacuum 72 is applied to the back surface of the sheet 70 in order to align the sheet 70 with the printing press bed 73. This vacuum suction ensures that the sheet's flatness is properly maintained in most cases, enabling good printing by the printing press. However, sheets sent from the feeder / cutter to the printing press are not always cut with a fold in the center. In some cases, the fold may be near the edge of the sheet. In such cases, it may not be possible to apply sufficient vacuum suction force to the sheet to maintain the flatness necessary for good printing. Also, the sheet may curl significantly at the fold 70a (Figures 7B, 7C), and the curled portion of the sheet may collide with the print head 71, potentially causing serious damage to the printing press.

[0025] Embodiments of the present invention also provide a sheet height tracking function 74. In embodiments of the present invention, the height tracking function comprises an optical detection system such as a Panasonic HL-G125 laser displacement sensor. The height tracking function adjusts the distance between the print head and the sheet in real time to address any lack of flatness in the sheet. The height tracking function detects the height of the sheet in a Z-fold. This height is used to determine when to activate the print head lifting system to adjust the height of the print head. In embodiments, when a curved portion of the sheet is detected, the print head rises to a height sufficient to avoid collision with the sheet 75 (Figure 7C). The print head may continue to operate, but the rise of the print head is recorded in the system, and sheets with unacceptable curvature are marked in the system for disposal rather than being counted as part of the production volume. In a first embodiment of the present invention, if the printer prints beyond a threshold deviation from flatness (e.g., the sheet thickness exceeds 5.5 mm), the sheet is tracked and discarded on the defective line. Thus, in this embodiment of the present invention, the system can continue to operate. Due to sheet defects such as warping or bending caused by Z-folding, printing continues up to a threshold sheet deviation of, for example, 5.5 mm. In a second embodiment of the present invention, if the inspection system detects that the print quality is outside the acceptable range, the sheet is discarded on the defective line. In such cases, the box that would have been printed on the defective sheet is reprinted on another sheet to meet production requirements.

[0026] In other embodiments, the print head moves continuously up and down to track the profile of the sheet and prints an acceptable image on the sheet as long as the amount of movement of the print head is within a predetermined tolerance range. System Architecture

[0027] Figure 8 is a block diagram illustrating the system architecture according to the present invention. The Z-fold sheet printing system shown in Figure 8 comprises a printing press 81, a pre-printing press 106 for sheet feeding and cutting, and a post-printing press 108 for die-cutting, folding, and gluing, each interconnected via communication through a cloud server 103. The pre-printing press and the post-printing press are each equipped with programmable logic controllers (PLCs) 107 and 109, respectively. The cloud server includes cloud software 104 and a cloud digital front-end (DFE) 105. The PLCs and cloud software for the pre-printing and post-printing presses are all located outside the printing press.

[0028] The printing press includes a raster image processor (RIP) 81 that provides a DFE to the printing press 102, which communicates with the cloud DFE. The printing press also includes a video PC 82 and a video board 84 that provide press software 83. The press software communicates with the printing press's DFE and a press score 99 in the press PC 101. The press score, in turn, communicates with the press UI 100 and a data logger 98. Thus, the press software manages the printing press's DFE, press score, press UI, and data logger collectively. The press score and data logger communicate with the printing press PLC 97.

[0029] The printer includes a carriage board 85 that receives data from a video board in a video PC. This carriage board provides operating instructions to an electronic board 88 that operates printhead 89, an electronic board 87 that operates printhead 90, an electronic board 86 that operates printhead 91, and an electronic board 93 that operates printhead 92. Those skilled in the art will understand that any number of printheads and corresponding electronic boards can be provided as needed.

[0030] In one embodiment of the present invention, Prescore also communicates with an inspection system 95 (see Figure 7) which includes a camera 96 ​​and inspection software 94.

[0031] The operation of the printing press, pre-printing press, and post-printing press is coordinated by the interaction between the pre-printing and post-printing press PLCs and the printing press Prescore 99. Furthermore, the coordination between the cloud and the printing press DFE enables the system to manufacture individual boxes in real time, as described above. In embodiments of the present invention, the system adjusts the size of the original print file to fit customized boxes, which vary from box to box. The system adjusts the file (image) to fit each box so that the dimensions of all print elements, such as logos and barcodes, are appropriate for the box. Some print elements, such as bare codes, may need to be maintained at a specific minimum or maximum size, while other print elements may be scaled to fit the box and cover it with the print. In such cases, the composition of the image printed on the box may be adjusted to accommodate the relative size changes of the various print elements. Processing system

[0032] Figure 9 is a block diagram showing an example of a processing system 1800 capable of implementing at least some of the operations described herein. For example, the components of the processing system 1800 may be hosted on a computing device that includes a threat detection platform. In another example, the components of the processing system 1800 may be hosted on a computing device on which queries are executed by the threat detection platform to retrieve emails or data, etc.

[0033] The processing system 1800 may also include a central processing unit (also called a “processor”) 1802, main memory 1806, non-volatile memory 1810, a network adapter 1812 (e.g., a network interface), a video display 1818, input / output devices 1820, a control unit 1822 (e.g., a keyboard or pointing device), a generator 1824 including a storage medium 1826, and a signal generating device 1830, all of which are communicatively connected to a bus 1816. The bus 1816 is shown as an abstraction representing one or more physical buses or point-to-point connections connected by appropriate bridges, adapters, or controllers. Therefore, bus 1816 can include system buses, PCI (Peripheral Component Interconnect) buses or PCI-Express buses, HyperTransport or ISA (Industry Standard Architecture) buses, SCSI (Small Computer System Interface) buses, USB (Universal Serial Bus), Inter-Integrated Circuit (I2C) buses, or the IEEE 1394 bus (also known as "Firewire").

[0034] The processing system 1800 may share a similar processor architecture to desktop computers, tablet computers, mobile phones, game consoles, music players, wearable electronic devices (e.g., watches or fitness trackers), network-connected ("smart") devices (e.g., televisions or home assistant devices), virtual reality / augmented reality systems (e.g., head-mounted displays), or other electronic devices capable of executing instruction sets (sequential or other instruction sets) that specify the actions that the processing system 1800 should perform.

[0035] Although the main memory 1806, non-volatile memory 1810, and storage medium 1826 are shown as a single medium, the terms “machine-readable medium” and “storage medium” should be interpreted to include a single or multiple medium (e.g., a centralized / distributed database and / or associated caches and servers) that can store one or more instruction sets 1828. The terms “machine-readable medium” and “storage medium” should be interpreted to include any medium that can store, encode, or transport instruction sets executed by the processing system 1800.

[0036] Generally, routines performed to implement embodiments of the present disclosure may be implemented as part of an operating system, or as a specific application, component, program, object, module, or instruction sequence (collectively referred to as a “computer program”). A computer program typically includes one or more instructions (e.g., instructions 1804, 1808, 1828) that are set at various points in time in different memories and storage devices within an electronic device. When read and executed by processor 1802, the instructions cause processing system 1800 to perform actions to execute elements, including various aspects of the present disclosure.

[0037] Furthermore, while embodiments have been described in the context of fully functional electronic devices, those skilled in the art will understand that several aspects of the present technology can be distributed as various forms of program products. This disclosure applies regardless of the specific type of machine-readable or computer-readable medium used for distribution.

[0038] Further examples of machine-readable and computer-readable media include recordable media such as volatile and non-volatile memory devices1810, removable disks, hard disk drives, optical discs (e.g., compact disc read-only memory (CD-ROM) and digital multipurpose disc (DVD)), and transmission media such as digital and analog communication links.

[0039] The network adapter 1812 enables the processing system 1800 to mediate data within the network 1814 to external entities of the processing system 1800 via any communication protocol supported by the processing system 1800 and the external entities. The network adapter 1812 may include a network adapter card, a wireless network interface card, a router, an access point, a wireless router, a switch, a multilayer switch, a protocol converter, a gateway, a bridge, a bridge router, a hub, a digital media receiver, a repeater, or any combination thereof.

[0040] The network adapter 1812 may include a firewall that controls and / or manages the authorization of access / proxy to data within the network. The firewall may also track levels of trust between different machines and / or applications. The firewall may consist of any number of modules with any combination of hardware, firmware, or software components that can enforce predetermined sets of access rights between machines and applications, between machines and machines, or between applications (e.g., regulating traffic flow and resource sharing between these entities). The firewall may further manage and / or access access control lists that show authorization details, including the rights of individuals, machines, or applications to access and manipulate objects, and the circumstances under which authorization rights apply.

[0041] The language used herein has been selected primarily for readability and explanatory purposes. It has not been selected to describe or limit the subject matter. Accordingly, the scope of the Art is intended to be limited not by this detailed description, but by the claims to be issued in an application relating thereto. Accordingly, the disclosure of various embodiments is illustrative, not limiting, to the scope of the Art as described in the following claims.

Claims

1. A feeder configured to supply a continuous sheet; A cutting machine configured to receive the sheet from the feeder and cut the sheet to a predetermined length; A single-pass inkjet printer configured to receive the cut sheet from the cutting machine, and configured to print an image on the cut sheet to decorate a box formed from the cut sheet; and A box manufacturing machine configured to receive the printed sheet from the single-pass inkjet printer, wherein the machine is configured to die-cut the printed sheet along the contour of a desired box while the box is laid flat, fold the printed sheet into the shape of the desired box, and then glue the folded sheet to complete the box. A system equipped with these features.

2. The system according to claim 1, wherein the continuous sheet comprises a continuous web of Z-fold material.

3. The system according to claim 1, wherein the length of the sheet defines the outer circumference of the box manufactured by the printing press, and the width of the sheet defines the height of the box manufactured by the printing press.

4. The system further comprises a processor configured to receive real-time commands for the coordinated control of the operation of the feeder, cutting machine, single-pass inkjet printer, and box manufacturing machine, and to operate the system in an uninterrupted sequence to feed the continuous sheet along the printer path, cut the continuous sheet to a desired length, print an image on the cut sheet, and die-cut, fold, and glue the image-printed sheet to form a box; The manufacturing of the box is carried out as a single set of continuous operations; and Any number of boxes of any shape and design can be formed on demand. The system according to claim 1.

5. Furthermore, the processor is configured to change the size of the image in real time to match the size of the box being manufactured. The system according to claim 1.

6. Furthermore, the processor is configured to control the inkjet printer so that the selected image is printed on each box, and the selected image is customized to match the contents of the box. The system according to claim 1.

7. Furthermore, the processor is configured to add targeted advertisements to the image printed on the box that are personalized for the recipient of the box and / or complement the contents of the box. The system according to claim 1.

8. The single-pass inkjet printer in question is further, A print bed configured to support a sheet during printing, wherein the print bed fixes the sheet to it during printing and applies a strong vacuum to the sheet, thereby firmly pulling the sheet to the print bed in a planar manner. The system according to claim 1.

9. If the vacuum is insufficient to hold the sheet to the print bed in order to maintain acceptable sheet flatness during printing, a sheet height tracking function is configured to adjust the distance between the print head and the sheet of the single-pass inkjet printer in real time to compensate for the lack of sheet flatness. Furthermore, the system according to claim 8 is further comprising.

10. The system according to claim 9, wherein when a curved portion of the sheet is detected, the sheet height tracking function raises the print head to a degree sufficient to avoid a collision between the sheet and the print head.

11. The system according to claim 10, wherein the print head is raised to mark the sheet that lacks acceptable flatness.

12. In order to track the flatness of the sheet, a mechanism is configured to continuously raise and lower the print head of the single-pass printer, Furthermore, the system according to claim 9 is further comprising.

13. A single-pass inkjet printer configured to receive cut sheets from a continuous web of Z-fold material, wherein the single-pass inkjet printer is configured to print an image on the cut sheets, which are curved at the Z-fold, in order to decorate a box formed from the cut sheets; and A print bed configured to support the sheet during printing, wherein the print bed further applies a strong vacuum to the sheet, thereby firmly pulling the sheet downward so that it aligns with the print bed at the Z-fold, and fixing the sheet in place during printing. A printing press equipped with the following features.

14. The printing press according to claim 13, further comprising a sheet height tracking mechanism configured to adjust the distance between the print head of the single-pass inkjet printer and the sheet in real time in order to compensate for a lack of flatness of the sheet when it is not possible to apply sufficient vacuum to the sheet via the print bed in order to maintain the flatness of the sheet at the Z-fold.

15. The printing press according to claim 14, wherein when a significantly curved portion of the sheet is detected, the sheet height tracking mechanism raises the print head to avoid a collision between the print head and the sheet.

16. The printing press according to claim 15, wherein the print head is raised to mark the sheet that lacks acceptable flatness.

17. In order to track the lack of flatness of the sheet at the Z-fold, a mechanism is configured to continuously raise and lower the print head of the single-pass printer, Furthermore, the printing press according to claim 14.

18. The cutting machine receives a continuous sheet from a feeder and cuts the sheet to a predetermined length; A single-pass inkjet printer receives the cut sheet from the cutting machine, and the single-pass inkjet printer prints an image on the cut sheet to decorate a box formed from the cut sheet; and A box manufacturing machine receives a printed sheet from a single-pass inkjet printer, and the box manufacturing machine, with the box laid flat, die-cuts the printed sheet along the contour of the desired box, folds the printed sheet into the shape of the box, and then glues the folded sheet to complete the box. How to prepare.

19. The method according to claim 18, wherein the continuous sheet comprises a continuous web of Z-fold material.

20. The method according to claim 18, wherein the length of the sheet defines the outer circumference of the box manufactured by the printing press, and the width of the sheet defines the height of the box manufactured by the printing press.

21. The processor receives commands in real time to coordinately control the operation of the feeder, cutting machine, single-pass inkjet printer, and box manufacturing machine, and operates the system in an uninterrupted sequence to feed the continuous sheet along the printer path, cut the continuous sheet to a desired length, print an image on the cut sheet, and then die-cut, fold, and glue the image-printed sheet to form the box; The manufacturing of the box is carried out as a single continuous operation set; and Any number of boxes of any shape and design can be formed on demand. The method according to claim 18.

22. The processor performs the process of changing the size of the image in real time to match the size of the box being manufactured. The method according to claim 18, comprising:

23. A step in which the processor controls the inkjet printer to print the selected image on each box, wherein the selected image is customized to match the contents of the box. Furthermore, the method according to claim 18.

24. The method according to claim 18, wherein the processor adds targeted advertising, personalized for the recipient of the box and matching the contents of the box, to an image printed on the box.

25. The single-pass inkjet printer in question A step of providing a print bed for supporting a sheet during printing, wherein the print bed fixes the sheet to it during printing and applies a strong vacuum to the sheet, thereby firmly pulling the sheet to the print bed in a planar manner. Furthermore, the method according to claim 18.

26. If the vacuum applied to the sheet via the print bed is insufficient to maintain acceptable sheet flatness, the process includes providing a sheet height tracking function to adjust the distance between the print head of the single-pass inkjet printer and the sheet in real time to compensate for the lack of flatness of the sheet. Furthermore, the method according to claim 25.

27. When a curved portion of the sheet is detected, the sheet height tracking mechanism performs the step of raising the print head to a degree sufficient to avoid a collision between the sheet and the print head. Furthermore, the method according to claim 26.

28. The process involves raising the print head and marking the sheet that lacks acceptable flatness with a discard mark, Furthermore, the method according to claim 27, comprising:

29. The process of tracking the flatness of the sheet by continuously raising and lowering the print head of the single-pass printing machine is as follows: Furthermore, the method according to claim 26.

30. A method for continuously printing on a continuous sheet of Z-fold material without image defects by sequentially and without interruption performing the following steps: The processor receives real-time instructions for the coordinated control of the operation of a feeder, a cutting machine, a single-pass inkjet printer, and a box-making machine, and operates the feeder, the cutting machine, the single-pass inkjet printer, and the box-making machine in an uninterrupted sequence to feed the continuous sheet of Z-fold material along the printer pass, cut the continuous sheet to a desired length, print an image on the cut sheet, then die-cut, fold, and glue the image-formed sheet to form the box; The manufacturing of the box is carried out as a single continuous operation set; and Any number of the boxes of any shape and design may be formed on demand; The processor issues the following instructions to the feeder, cutting machine, single-pass inkjet printer, and box manufacturing machine: Instructions to supply the Z-fold material to the cutting machine; Instructions to cut the Z-fold material; An instruction to receive the cut Z-fold material in the single-pass inkjet printer; Instructions to be printed on the cut Z-fold material; During printing, an instruction is given to apply a strong vacuum to the cut Z-fold material and firmly pull the sheet down so that it aligns with the print bed and the plane; If the vacuum applied to the sheet via the print bed is insufficient to maintain acceptable sheet flatness, the sheet height tracking function is used to adjust the distance between the print head of the single-pass inkjet printer and the sheet in real time to compensate for the lack of sheet flatness; and Instructions for supplying cut and printed Z-fold material to the box manufacturing machine, die-cutting, folding, and gluing to form the completed box, The process of giving A method for providing this.

Images