A printer for web material

Abstract

A printer for web material includes a conveyer configured for traversing a web along a machine direction. The printer also includes a first printhead. A second printhead is spaced from the first printhead along the machine direction. A vacuum port is disposed between the first and second printheads along the machine direction.

Description

[0001] KCX-2148-PCT / 65125303PCT01

[0002] A PRINTER FOR WEB MATERIAL

[0003] BACKGROUND

[0004] Graphics are commonly printed on diapers and training pants to increase aesthetic appeal. For example, the outer covers of such absorbent articles can be imprinted with images, such as designs and characters, that are pleasing to the wearer and caregiver. The image may be printed onto the outer cover material prior to assembly of the absorbent garment. Images may also be printed on other absorbent articles, such as feminine healthcare products, adult incontinence garments, and bandages.

[0005] Ink jet printers provide flexible image printing and can apply inks to a variety of substrates, including webs used for absorbent articles. Generally, inkjet printers discharge small droplets of ink onto a substrate in a predetermined pattern. Inkjet printers for moving substrates typically include multiple printheads closely arranged in series. Images can be formed at production line speeds where the substrate moves rapidly (e.g., 100 fpm and more) beneath the printheads.

[0006] Inkjet printers can generate significant heat during operation. Moreover, dust and particulates can accumulate on the printers as substrates traverse past the printers. The dust accumulation can be difficult to clean and lead to wasteful wrinkles in the substrate.

[0007] Systems and methods for limiting dust and heat accumulation at inkjet printers for moving substrates would be useful.

[0008] SUMMARY

[0009] In general, the present disclosure is directed to a printer system, such as a staggered multicolor printer, that includes features for assisting with mounting printheads to reduce ink and dust buildup and other process issues during operation. Mounts of the printer system may suspend multiple staggered printheads and a vacuum port may be disposed between adjacent printheads to remove dust and heat away from the printheads. The printer system may advantageously reduce dust buildup by drawing dust from a nonwoven web and other sources away from the printheads. Thus, the printer system may remain online and operational longer between cleaning sessions compared to conventional printer systems. Moreover, cleanup times for the printer system may be reduced relative to conventional printer systems. The printer system also reduces the risk of material waste due to heat induced wrinkles in the printed material.

[0010] In one example embodiment, a printer for web material includes a conveyer configured for traversing a web along a machine direction. The printer also includes a first printhead. A second KCX-2148-PCT / 65125303PCT01 printhead is spaced from the first printhead along the machine direction. A vacuum port is disposed between the first and second printheads along the machine direction.

[0011] In another example embodiment, a printer for web material includes a conveyer configured for traversing a web along a machine direction. The printer also includes a first printhead. A second printhead is positioned adjacent the first printhead. The second printhead partially offset from the first printhead along a cross direction that is perpendicular to the machine direction. A third printhead is spaced from the first and second printheads along the machine direction. A fourth printhead is positioned adjacent the third printhead. The fourth printhead is partially offset from the third printhead along the cross direction. A vacuum port is disposed between the second and third printheads along the machine direction.

[0012] In another example embodiment, a method for printing on a web material, includes: traversing web along a machine direction on a conveyer; applying ink from a first printhead and a second printhead onto the web, the second printhead spaced from the first printhead along the machine direction; and drawing air away from the web via a vacuum port disposed between the first and second printheads along the machine direction.

[0013] These and other features, aspects and advantages of the present disclosure will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and, together with the description, serve to explain the principles of the disclosure.

[0014] BRIEF DESCRIPTION OF THE DRAWINGS

[0015] A full and enabling disclosure of the present disclosure, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

[0016] FIG. 1 is a side schematic view of a printing system for web material according to an example embodiment of the present subject matter.

[0017] FIG. 2 is a schematic plan view of a printer and a vacuum port of the example printing system of FIG. 1.

[0018] FIG. 3 is side schematic view of portions of the printer and the vacuum port of the example printing system of FIG. 1.

[0019] FIG. 4 is perspective view of the printer and the vacuum port of the example printing system of FIG.

[0020] 1.

[0021] FIG. 5 is a computational fluid dynamics heat map of a printing system without a vacuum port during KCX-2148-PCT / 65125303PCT01 operation of the printing system.

[0022] FIG. 6 is a computational fluid dynamics heat map of a printing system with a vacuum port during operation of the printing system.

[0023] FIGS. 7 through 10 are schematic views of printing systems for web material according to other example embodiments of the present subject matter.

[0024] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

[0025] DETAILED DESCRIPTION

[0026] The following description should be read with reference to the drawings in which similar elements in different drawings are numbered the same. The description and the drawings, which are not necessarily to scale, depict illustrative embodiments and are not intended to limit the scope of the disclosure.

[0027] Although some suitable dimensions, ranges and / or values pertaining to various components, features and / or specifications are disclosed, one of skill in the art, incited by the present disclosure, would understand desired dimensions, ranges and / or values may deviate from those expressly disclosed.

[0028] When introducing elements of the present disclosure or the preferred embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. As used herein, the terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. For example, the approximating language may refer to being within a ten percent (10%) margin.

[0029] Definitions:

[0030] As used herein, the terms “chemistry” or “chemistries” are intended to include and refer to any and all applications, inks (other than phase-change inks), compositions, formulations, and the like (including those having solids and / or particulates) which may be processed by printheads. It is KCX-2148-PCT / 65125303PCT01 desirable, but not necessary, that the terms “chemistry” or “chemistries” be directed to such applications, inks, compositions, formulations, and the like which are compatible with phase-change inks. Suitable chemistries include, but are not limited to, medicaments, inks, waxes, paints, lotions, ointments, skin health agents, topical applications, and the like or combinations thereof. It will be appreciated that one of such chemistries may be a medium which is used to carry or transport phasechange inks.

[0031] As used herein, the term “fabric” refers to all of the woven, knitted, and nonwoven fibrous webs, as well as paper, foam, film, or the like.

[0032] As used herein, the term “layer” when used in the singular can have the dual meaning of a single element or a plurality of elements.

[0033] As used herein the terms “nonwoven” and “nonwoven fabric or web” mean a web having a structure of individual fibers, filaments or threads which are interlaid, but not in an identifiable manner as in a knitted fabric. Nonwoven fabrics or webs have been formed from many processes such as for example, meltblowing processes, spunbonding processes, and bonded carded web processes. The basis weight of nonwoven fabrics is usually expressed in ounces of material per square yard (osy) or grams per square meter (gsm) and the fiber diameters useful are usually expressed in microns. (Note that to convert from osy to gsm, multiply osy by 33.91).

[0034] As used herein, the term “personal care product” or “absorbent product” means diapers, training pants, swim wear, absorbent underpants, baby wipes, adult incontinence products, sanitary wipes, wet wipes, feminine hygiene products, nursing pads, hygiene and absorbent products and the like.

[0035] As used herein, the term “phase-change” application, chemistry, ink, liquid, material or the like refers to a material which is processed in a liquid or substantially liquid state and then solidifies, returns to its natural state when cooled, cures, cross-links, or the like.

[0036] As used herein, the term “printhead” means a structure that includes ports for firing one or more inks onto a material. The structure may also include other components, such as an ink reservoir, a pump, piezoelectric materials or heating elements, and control circuitry, e.g., within a common housing.

[0037] As used herein, the term “printer” means an assembly of multiple printheads operable to fire one or more inks onto a web material traversing below the printheads.

[0038] These terms may be defined with additional language in the remaining portions of the specification. KCX-2148-PCT / 65125303PCT01

[0039] Each example is provided by way of explanation and is not meant as a limitation. For example, features illustrated or described as part of one embodiment or figure can be used on another embodiment or figure to yield yet another embodiment. It is intended that the present disclosure include such modifications and variations.

[0040] Many modifications and variations of the present disclosure can be made without departing from the spirit and scope thereof. Therefore, the exemplary embodiments described above should not be used to limit the scope of the invention.

[0041] Printer:

[0042] FIG. 1 is a schematic view of a system 100 for printing onto a material, such as a web. In example embodiments, the system 100 may be disposed in-line with other process components for forming absorbent articles, such as diapers. In other example embodiments, the system 100 may be configured offline for printing onto a web that is subsequently incorporated into absorbent articles, such as diapers. For instance, the system 100 may print onto a web forming an outer cover of the absorbent articles, and the printed web may then be brought to a line for forming the absorbent articles with the printed web. The composition and configuration of absorbent article assembly lines is well understood by those of ordinary skill in the art.

[0043] As shown in FIG. 1 , a web material 102 may be fed through a guide assembly 110. Idlers 112 of the guide system 110 may be configured compatible with the material 102 passing over the idlers 112 such that the material 102 passes through a printer assembly 120 in a substantially wrinkle-free fashion. Moreover, the idlers 112 may be adjustable such that a desired level of tension may be applied to the material 102 to eliminate or reduce the wrinkles in the material 102 passing through the printer assembly 120. While reference is made to idlers 112, it is also intended the present subject matter may utilize other mechanisms to maintain or adjust the tension on the material 102 as the material 102 passes under printheads of the printer assembly 120.

[0044] The printer assembly 120 is configured for applying ink onto the material 102 as the material 102 passes by (e.g., under) the printer assembly 120. For example, the printer assembly 120 includes a plurality of printheads disposed in series along a machine direction M of the system 100. In the example embodiment shown in FIG. 1, the printer assembly 120 includes a first printhead 122, a second printhead 124, a third printhead 126, and a fourth printhead 128. It will be understood that the printer assembly 120 may include two, three, five, or more printheads in other example embodiments. Each of the printheads 122, 124, 126, 128 is configured for discharging ink onto the material 102. For instance, the printer assembly 120 may be disposed above the material 102, and the printer assembly KCX-2148-PCT / 65125303PCT01

[0045] 120 may be configured for discharging ink from the printheads 122, 124, 126, 128 downwardly onto the material 102.

[0046] As shown in FIG. 2, the printheads 122, 124, 126, 128 may be disposed in series along the machine direction M. For example, the first printhead 122 may be positioned furthest upstream along the machine direction M relative to the second, third, and fourth printheads 124, 126, 128 as the material 102 moves along the machine direction M. Conversely, the fourth printhead 128 may be positioned furthest downstream along the machine direction M relative to the first, second, and third printheads 122, 124, 126 as the material 102 moves along the machine direction M. The second and third printheads 124. 126 may be disposed between the first and fourth printheads 122, 128 along the machine direction M. Moreover, the second printhead 124 may be disposed between the first and third printheads 122, 126 along the machine direction M, and the third printhead 126 may be disposed between the second and fourth printheads 124, 128 along the machine direction M.

[0047] It will be understood that the number and arrangement of the printheads 122, 124, 126, 128 shown in FIG. 2 is provided by way of example only. Other numbers of printheads and / or arrangements of the printheads may be used in other example embodiments. For instance, FIGS. 7 through 10 show arrangements of printheads according to various example embodiments. In FIG. 7, a printer assembly 200 includes four (4) printheads 210 arranged in the manner generally corresponding to FIG. 2. In FIG. 8, a printer assembly 300 includes four (4) printheads 310 arranged in-line with one another along the machine direction M. In FIG. 9, a printer assembly 400 includes two (2) printheads 410 arranged in-line with one another along the machine direction M. In FIG. 8, a printer assembly 500 includes six (6) printheads 510 with two sets of three (3) printheads 510 arranged partially offset along the cross direction C. Again, other numbers of printheads and / or arrangements of the printheads may be used in other example embodiments.

[0048] Turning back to FIG. 2, the first and second printheads 122, 124 may be disposed adjacent to each other along the machine direction M. Thus, e.g., a gap between the first and second printheads 122, 124 may be no greater than five centimeters (5 cm), such as no greater than three centimeters (3 cm), such as no greater than one centimeter (1 cm), along the machine direction M. The first and second printheads 122, 124 may be partially offset along a cross direction C, e.g., that is perpendicular to the machine direction M and a transverse direction T (FIG. 1). Thus, e.g., the first and second printheads 122, 124 may partially overlap along the cross direction C. In example embodiments, less than half of the widths of the first and second printheads 122, 124 may overlap along the cross direction C.

[0049] The third and fourth printheads 126, 128 may also be disposed adjacent to each other along KCX-2148-PCT / 65125303PCT01 the machine direction M. Thus, e.g., a gap between the third and fourth printheads 126, 128 may be no greater than five centimeters (5 cm), such as no greater than three centimeters (3 cm), such as no greater than one centimeter (1 cm), along the machine direction M. The third and fourth printheads

[0050] 126, 128 may be partially offset along the cross direction C. Thus, e.g., the third and fourth printheads

[0051] 126, 128 may partially overlap along the cross direction C. In example embodiments, less than half of the widths of the third and fourth printheads 126, 128 may overlap along the cross direction C.

[0052] The first and second printheads 122, 124 may be spaced from the third and fourth printheads

[0053] 126, 128 along the machine direction M. For example, a gap between the second and third printheads 124, 126 may be no less than two centimeters (2 cm), such as no less than three centimeters (3 cm), such as no less than five centimeters (5 cm), such as no less than six centimeters (6 cm), along the machine direction M. In example embodiments, the gap between the second and third printheads 124, 126 may be no greater than twenty-four centimeters (24 cm), such as no greater than twenty centimeters (20 cm), such as no greater than sixteen centimeters (16 cm), such as no greater than twelve centimeters (12 cm), such as no greater than ten centimeters (10 cm), along the machine direction M. The gap between the first and second printheads 122, 124 and the third and fourth printheads 126, 128 may be sized for receipt of a vacuum port or duct 130 as described in greater detail below. The first printhead 122 may also be aligned with the third printhead 126 along the machine direction M. Similarly, the second printhead 124 may be aligned with the fourth printhead 128 along the machine direction M.

[0054] The arrangement of the printheads 122, 124, 126, 128 described above may advantageously assist with application of ink while the material 102 traverses at high speeds relative to the printer assembly 120. For example, a speed of the material 102 may be no less than three hundred meters per minute (300 m / min), such as no less than five hundred meters per minute (500 m / min), such as no less than six hundred meters per minute (600 m / min), such as no less than eight hundred meters per minute (800 m / min). In example embodiments, the speed of the material 102 may be no greater than one thousand meters per minute (1000 m / min). The arrangement of the printheads 122, 124, 126, 128 may assist with forming quality images with ink from the printheads 122, 124, 126, 128 while the material 102 traverses at high speeds relative to the printer assembly 120.

[0055] In example embodiments, the printheads 122, 124, 126, 128 may be operable to print phasechange inks, such as hot melt ink compositions, or other inks. The printheads 122, 124, 126, 128 may jet droplets of one or more inks onto the material 102 so that an image is formed on the material 102. In example embodiments, each of the printheads 122, 124, 126, 128 may be configured to apply the same single-color ink to the material 102. In other example embodiments, each of the printheads 122, KCX-2148-PCT / 65125303PCT01

[0056] 124. 126. 128 may be configured to apply a different single-color inks to the material 102. The colors may include one or more of cyan, magenta, yellow, black, red, green, blue, and\ white.

[0057] Operation of the printheads 122, 124, 126, 128 may be regulated by a controller (not shown) that is in communication with the printheads 122, 124, 126, 128. The controller may be configured for operating in multiple modes and may control the printheads 122, 124, 126, 128 such that the printheads 122, 124, 126, 128 act together or independently from one another. It will be appreciated that any number of controllers may be used depending in part upon the number of printheads each controller is in communication with. The controller may include manual, computer controlled, or computer regulated control elements. Exemplary controller may include, but are not limited to, manual switches, line driven switches, photo-optic sensors, software driven switching circuits and so forth.

[0058] Turning back to FIG. 1 , the system 100 may also include a conveyer 140. The conveyer 140 may be configured for supporting the material 102 in a position facing the printer assembly 120. As noted above, the printheads 122, 124, 126, 128 may be disposed in series along the machine direction M. The ends of the printheads 122, 124, 126, 128 (where outlet portions from which ink droplets are discharged) are all spaced closely with the conveyer 140. As an example, the printheads 122, 124,

[0059] 126. 128 may be spaced from the conveyer 140 such that a gap between an upper surface of the material 102 and the printheads 122, 124, 126, 128 may be between about one millimeter (1 mm) and about three millimeters (3 mm). In example embodiments, the conveyer 140 positions the material 102 so that in operation, the spacing of each printhead 122, 124, 126, 128 from the material 102 may be about one millimeter (1 mm) to about five millimeters (5 mm) in operation. The gap between the printheads 122, 124, 126, 128 and the conveyer 140 may also be adjustable. For instance, the gap may be larger when not in use for facilitating threading the material 102 through the printer assembly 120 and / or cleaning of the printer assembly 120. Such movement may be accomplished by linear actuators 148.

[0060] In example embodiments, the conveyer 140 may also be configured for assisting with transporting the material 102 relative to the printer assembly 120. For example, the conveyer 140 may include a belt 142, a rack 144, and rollers 146. The belt 142 may be rotatably mounted to the rack 144 via the rollers 146. The material 102 may be disposed on the belt 142 between the printer assembly 120 and the belt 142, e.g., along a transverse direction T, which is mutually perpendicular to the machine direction M and the cross direction C (FIG. 2 and oriented into and out of the page in the view of FIG. 1). Thus, the material 102 may translate with the belt 142 during operation of the system 100 to support and transport the material 102 relative to the printer assembly 120. For instance, a speed of the belt 142 may be matched to the material 102, and the rack 144 may support the belt 142 and KCX-2148-PCT / 65125303PCT01 material 102 to limit deflection of the belt 142 and material 102 relative to the printer assembly 120 (e.g., away from the printer assembly 120 along the transverse direction T). Thus, the conveyer 140 may assist with maintaining a consistent gap between the material 102 and the printer assembly 120 during operation of the system 100. The linear actuators 148 may be coupled to the rack 144 to assist with adjusting the size of the gap between the printheads 122, 124, 126, 128 and the conveyer 140.

[0061] Suitable printheads 122, 124, 126, 128 that may be used in example embodiments are Galaxy JA 256 / 80 AAA ink jet jetting assemblies available from FUJIFILM Dimatix, Inc. of Lebanon, N.H. These printheads 122, 124, 126, 128 may each have four piezoelectric slices with each slice having an independent electrical circuit. Each circuit is associated with two hundred and fifty-six (256) orifices for a total of one thousand, twenty-four (1024) orifices per printhead. Each of the orifices can be individually addressed so that the controller can select which of the of one thousand, twenty-four orifices are to be fired in each cycle. The orifices are spaced apart about 0.254 millimeter±0.245 millimeter. It will be understood that other printheads having a different number of orifices and / or orifices with different spacings could be used without departing from the scope of the present subject matter. The printheads 122, 124, 126, 128 may each have an ink reservoir on the printhead that has an ink level sensor that can be used to signal an ink supply system to deliver additional ink to the printhead.

[0062] The printheads 122, 124, 126, 128 of the printer assembly 120 may desirably be rigidly mounted at precise locations on a frame 150. The frame 150 may advantageously allow all of the printheads 122, 124, 126, 128 to be precisely located. The frame 150 or another suitable fixture may rigidly couple the printheads 122, 124, 126, 128 together at precise locations such that the positions of the printheads 122, 124, 126, 128 relative to each other in the machine direction M and cross direction C are defined and such that a precise gap between each printhead orifice and the top surface of the material 102 is maintained. The alignment of the printheads with each other on a centerline is in example embodiments within from about 0.002 centimeter to 0.01 centimeter.

[0063] In example embodiments, the printheads 122, 124, 126, 128 may be operated at one hundred and fifty volts (150 V) at frequencies ranging from zero kilohertz (0 kHz) to twenty kilohertz (20 kHz). The nominal drop mass of each droplet ejected by the printheads 122, 124, 126, 128 may be measured to be about eighty picolitres (80 pL), which may correspond to the standard drop mass specification for the printhead. In one example aspect, the resolution of the printheads 122, 124, 126, 128 may be set at one hundred dots per inch (100 dpi) and the material 102 may be run at a speed greater than six hundred meters per minute (600 m / min). However, it is to be understood that other printheads at different operational settings may be in example embodiments of the present subject KCX-2148-PCT / 65125303PCT01 matter. Application of ink by inkjet printheads to high speed substrates is also discussed in U.S. Patent No. 6,957,884, entitled HIGH-SPEED INKJET PRINTING FOR VIBRANT AND CROCKFAST GRAPHICS ON WEB MATERIALS OR END-PRODUCTS, the disclosure of which is incorporated herein by reference.

[0064] During operation, the system 100 can generate dust, which can lead to accumulation of dust and ink from the printheads 122, 124, 126, 128 on various components of the system 100, such as the printheads 122, 124, 126, 128, the frame 150, and the conveyer 140. As an example, the material 102 may shed dust as the material 102 translates through the system 100. For instance, the material 102 may shed dust as the material 102 turns on the idlers 112. The ink from the printheads 122, 124, 126, 128 may impact the dust, and the ink laden dust may settle on various components of the system 100. When the ink laden dust settles on or adjacent the orifices of the printheads 122, 124, 126, 128, the ink laden dust can obstruct operation of the printheads 122, 124, 126, 128. Thus, the system 100 may require periodic cleaning to remove the ink laden dust and ensure unobstructed operation of the printheads 122, 124, 126, 128 towards the material 102. Such cleaning can be time and labor intensive and can require taking the system offline, which limits productivity. The system 100 may include features for removing dust from the system 100, such as from proximate the printheads 122, 124, 126, 128.

[0065] During operation, the system 100 can also generate heat, which can negatively affect components of the system 100. As an example, the printheads 122, 124, 126, 128 can emit heat during operation, and the heat can transfer to the material 102 as the material 102 translates past the printer assembly 120. The heat can cause the material 102 to deform and wrinkle as the printheads 122, 124, 126, 128 apply ink to the material 102, which can result in improper image formation on the material 102. Material with misprints is generally scrapped, which is inefficient. The system 100 may include features for removing heat from the system 100, such as from proximate the printheads 122, 124, 126, 128.

[0066] As shown in FIGS. 1 through 3, the system 100 may include a vacuum port or duct 130. The vacuum duct 130 may be configured for drawing air (and thus dust and heat) away from the printer assembly 120. As shown in FIG. 1, the vacuum duct 130 may be disposed between the second printhead 124 and the third printhead 126 along the machine direction M. Thus, e.g., the first and second printheads 122, 124 may be disposed upstream of the vacuum duct 130 along the machine direction M, and the third and fourth printheads 126, 128 along the machine direction M. As shown in FIG. 1, an inlet 132 of the vacuum duct 130 may be disposed generally coplanar with bottom surfaces of the printheads 122, 124, 126, 128 with the orifices in example embodiments. KCX-2148-PCT / 65125303PCT01

[0067] The vacuum duct 130 may be connected to a vacuum source, such as a pump. As shown in FIG. 3, during operation, reduced pressure at the inlet 132 of the vacuum duct 130 may draw air (shown with arrows A) into the vacuum duct 130. Moreover, the air A entering the vacuum duct 130 from a gap G between an upper surface of the material 102 and the printheads 122, 124, 126, 128 may also include dust from the material 102 and other sources. Thus, the vacuum duct 130 may remove dust from proximate the printer assembly 120, and the vacuum duct 130 may limit or prevent dust accumulation on the frame 150 and / or the printheads 122, 124, 126, 128 by collecting and removing dust from at the frame 150 and / or the printheads 122, 124, 126, 128.

[0068] The vacuum duct 130 may also remove heat from proximate the printer assembly 120. For instance, heated air A adjacent the printheads 122, 124, 126, 128 may be drawn into the vacuum duct 130, and colder air A may flow into the gap between the upper surface of the material 102 and the printheads 122, 124, 126, 128. The printheads 122, 124, 126, 128 may reject heat to the relatively cool air A entering the gap between the upper surface of the material 102 and the printheads 122, 124, 126, 128, and the vacuum duct 130 may again draw the heated air A into the vacuum duct 130 and away from the printheads 122, 124, 126, 128. Thus, the vacuum duct 130 may remove heat from proximate the printer assembly 120, and the vacuum duct 130 may limit or prevent deformation or wrinkling of the material 102 by removing heat away from the printheads 122, 124, 126, 128 prior to the material 102 being heated and deformed by heat from the printheads 122, 124, 126, 128.

[0069] The vacuum duct 130 may also form a thermal break between the upstream first and second printheads 122, 124 and the downstream third and fourth printheads 126, 128 along the machine direction M. For example, heat transfer from the upstream first and second printheads 122, 124 to the downstream third and fourth printheads 126, 128 along the machine direction M may be limited or obstructed by the vacuum duct 130. Moreover, the vacuum duct 130 may obstruct thermal conductivity between the upstream first and second printheads 122, 124 and the downstream third and fourth printheads 126, 128 along the machine direction M. Disposing the vacuum duct 130 between the second printhead 124 and the third printhead 126 along the machine direction M may also limit available surface area facing the gap G between an upper surface of the material 102 and the printheads 122, 124, 126, 128, which can reduce the accumulation of dust and ink.

[0070] The vacuum duct 130 may be sized to facilitate removal of dust and heat from proximate the printer assembly 120. For instance, as shown in FIG. 2, the vacuum duct 130 may have a width WV along the cross direction C. The first printhead 122 may also have a width WP along the cross direction C. The width WV of the vacuum duct 130 may be equal to or greater than the width WP of the first printhead 122. For instance, the width WV of the vacuum duct 130 may be no less than three KCX-2148-PCT / 65125303PCT01 centimeters (3 cm) greater than the width WP of the first printhead 122. It will be understood that the widths of the second, third, and fourth printheads 124, 126, 128 may be the same or similar to the width WP of the first printhead 122 in example embodiments. As another example, as shown in FIG. 2, the first and second printheads 122,124 may have a collective width WC between opposite sides of the first and second printheads 122,124 along the cross direction C. The width WV of the vacuum duct 130 may be equal to or greater than the collective width WC of the first and second printheads 122,124. For instance, the width WV of the vacuum duct 130 may be no less than three centimeters (3 cm) greater than the collective width WC of the first and second printheads 122,124. Such sizing of the vacuum duct 130 relative to the printheads 122, 124, 126, 128 may facilitate removal of dust and heat from proximate the printer assembly 120.

[0071] The vacuum duct 130 may also have a depth D along the machine direction M. The width WV of the vacuum duct 130 may be no less than twice (2X), such as no less than three times (3X), such as no less than four times (4X), such as no less than five times (5X), the depth D of the vacuum duct 130. Such sizing of the vacuum duct 130 relative to the printheads 122, 124, 126, 128 may facilitate removal of dust and heat from proximate the printer assembly 120. Moreover, the vacuum duct 130 may be elongated along the machine direction M to facilitate removal of dust and heat along the width of the material 102 as the material 102 traverses under the vacuum duct 130 along the machine direction M. In example embodiments, the width WV of the vacuum duct 130 may be no less than six and a half centimeters (6.5 cm) and no greater than fifty centimeters (50 cm), and the depth D of the vacuum duct 130 may be no less than one centimeter (1 cm) and no greater than twenty centimeters (20 cm).

[0072] The frame 150 may also suspend the printheads 122, 124, 126, 128 over the material 102 and belt 142. For instance, the printheads 122, 124, 126, 128 may be suspended such that support structure for the printheads 122, 124, 126, 128 is disposed away from the printheads 122, 124, 126, 128 along the transverse direction T. Such spacing may limit or prevent ink and dust accumulation on the frame 150. An example, the frame 150 may be spaced from the bottom surfaces of the printheads 122, 124, 126, 128 with the orifices by no less than ten centimeters (10 cm) in example embodiments. Thus, e.g., the frame 150 may support tops or sides of the printheads 122, 124, 126, 128 rather than the bottoms of the printheads 122, 124, 126, 128.

[0073] The system 100 may also include other vacuum chutes in example embodiments. For example, as shown in FIG. 1 , the system 100 may include an upstream vacuum chute 134. The upstream vacuum chute 134 may be disposed upstream of the first printhead 122 along the machine direction M, e.g., at one or the idlers 112. The upstream vacuum chute 134 may be connected to a KCX-2148-PCT / 65125303PCT01 vacuum source, such as a pump. During operation, reduced pressure at an inlet of the upstream vacuum chute 134 may draw air into the upstream vacuum chute 134. The air entering the upstream vacuum chute 134 may dust from the material 102 and other sources. Thus, the upstream vacuum chute 134 may remove dust from proximate the printer assembly 120, and the upstream vacuum chute 134 may limit or prevent dust accumulation on the printheads 122, 124, 126, 128 by collecting and removing dust from an upstream end of the printer assembly 120.

[0074] As another example, as shown in FIG. 1 , the system 100 may include one or more downstream vacuum chutes 136, 137, 138. The downstream vacuum chute(s) 136, 137, 138 may be disposed downstream of the fourth printhead 128 along the machine direction M, e.g , at one or the idlers 112 and / or rollers 146. The downstream vacuum chute(s) 136, 137, 138 may be connected to a vacuum source(s), such as a pump. During operation, reduced pressure at inlets of the downstream vacuum chute(s) 136, 137, 138 may draw air into the downstream vacuum chute(s) 136, 137, 138. The air entering the downstream vacuum chute(s) 136, 137, 138 may dust from the material 102 and other sources. Thus, the downstream vacuum chute(s) 136, 137, 138 may remove dust from proximate the printer assembly 120, and the downstream vacuum chute(s) 136, 137, 138 may limit or prevent dust accumulation on the printheads 122, 124, 126, 128 by collecting and removing dust from a downstream end of the printer assembly 120.

[0075] As noted above, the vacuum duct 130 may remove heat from proximate the printer assembly 120. FIGS. 5 and 6 are computational fluid dynamics heat maps of the printheads 122, 124, 126, 128. In FIG. 5, the vacuum duct 130 is inactive and is not drawing heated air adjacent the printheads 122, 124, 126, 128 into the vacuum duct 130. Conversely, in FIG. 6, the vacuum duct 130 is active and draws heated air adjacent the printheads 122, 124, 126, 128 into the vacuum duct 130. As may be seen in the computational fluid dynamics heat maps of FIGS. 5 and 6, drawing air into the vacuum duct 130 may significantly reduce the temperature of the printheads 122, 124, 126, 128 and surrounding components of the system 100. For example, without operation of the vacuum duct 130 significant portions of the printheads 122, 124, 126, 128 (particularly the third and fourth printheads 126, 128) may exceed ninety-three degrees Celsius, which can negatively affect operation of the system 100, e.g., by deforming the material 102. In contrast, operation of the vacuum duct 130 may limit the maximum temperature for most of the printheads 122, 124, 126, 128 to less than sixty degrees Celsius, which can facilitate operation of the system 100, e.g., by limiting or preventing deformation of the material 102. In FIGS. 5 and 6, the printheads 122, 124, 126, 128 may be heated to temperatures up to one hundred and twenty-five degrees Celsius.

[0076] These and other modifications and variations to the present invention may be practiced by KCX-2148-PCT / 65125303PCT01 those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention so further described in such appended claims.

[0077] KCX-2148-PCT / 65125303PCT01

[0078] EXAMPLE EMBODIMENTS

[0079] First example embodiment: A printer for web material, comprising: a conveyer configured for traversing a web along a machine direction; a first printhead; a second printhead spaced from the first printhead along the machine direction; and a vacuum port disposed between the first and second printheads along the machine direction.

[0080] Second example embodiment: The printer of the first example embodiment, wherein: the conveyer comprises a belt spaced from the first and second printheads by a gap along a transverse direction that is perpendicular to the machine direction; and the vacuum port is configured for drawing air away from the gap

[0081] Third example embodiment: The printer of either the first example embodiment or the second example embodiment, wherein the gap is no greater than eight millimeters.

[0082] Fourth example embodiment: The printer of any one of the first through third example embodiments, wherein the first printhead comprises a plurality of ink orifices spaced apart along a cross direction on the first printhead.

[0083] Fifth example embodiment: The printer of any one of the first through fourth example embodiments, further comprising a third printhead positioned adjacent the first printhead, the third printhead partially offset from the first printhead along a cross direction.

[0084] Sixth example embodiment: The printer of any one of the first through fifth example embodiments, wherein a width of the vacuum port along a cross direction is greater than a width of the first printhead along the cross direction.

[0085] Seventh example embodiment: The printer of any one of the first through sixth example embodiments, wherein: the vacuum port has a depth along the machine direction and a width along a cross direction; and the width of the vacuum port is no less than twice the depth of the vacuum port.

[0086] Eighth example embodiment: The printer of any one of the first through seventh example embodiments, wherein the vacuum port is configured for drawing air away from a gap between the vacuum port and the conveyer.

[0087] Nineth example embodiment: The printer of any one of the first through eighth example embodiments, further comprising one or both of: an upstream vacuum chute disposed upstream of the first printhead along the machine direction; and a downstream vacuum chute disposed downstream of the second printhead along the machine direction.

[0088] Tenth example embodiment: The printer of any one of the first through nineth example embodiments, further comprising a frame for supporting the first and second printheads over the KCX-2148-PCT / 65125303PCT01 conveyer, wherein the frame is spaced from ink orifices of the first and second printheads along a transverse direction.

[0089] Eleventh example embodiment: A printer for web material, comprising: a conveyer configured for traversing a web along a machine direction; a first printhead; a second printhead positioned adjacent the first printhead, the second printhead partially offset from the first printhead along a cross direction that is perpendicular to the machine direction; a third printhead spaced from the first and second printheads along the machine direction; a fourth printhead positioned adjacent the third printhead, the fourth printhead partially offset from the third printhead along the cross direction; and a vacuum port disposed between the second and third printheads along the machine direction.

[0090] Twelfth example embodiment: The printer of the eleventh example embodiment, wherein: the conveyer comprises a belt spaced from the first and third printheads by a gap along a transverse direction that is perpendicular to the machine and cross directions; and the vacuum port is configured for drawing air away from the gap.

[0091] Thirteenth example embodiment: The printer of any one of the eleventh example embodiment or the twelfth example embodiment, wherein the gap is no greater than eight millimeters.

[0092] Fourteenth example embodiment: The printer of any one of the eleventh through thirteenth example embodiments, wherein the first printhead comprises a plurality of ink orifices spaced apart along the cross direction on the first printhead.

[0093] Fifteenth example embodiment: The printer of any one of the eleventh through fourteenth example embodiments, wherein a width of the vacuum port along the cross direction is greater than a collective width of the first and second printheads along the cross direction.

[0094] Sixteenth example embodiment: The printer of any one of the eleventh through fifteenth example embodiments, wherein: the vacuum port has a depth along the machine direction and a width along the cross direction; and the width of the vacuum port is no less than twice the depth of the vacuum port.

[0095] Seventeenth example embodiment: The printer of any one of the eleventh through sixteenth example embodiments, wherein the vacuum port is configured for drawing air away from a gap between the vacuum port and the conveyer.

[0096] Eighteenth example embodiment: The printer of any one of the eleventh through seventeenth example embodiments, further comprising one or both of: an upstream vacuum chute disposed upstream of the first printhead along the machine direction; and a downstream vacuum chute disposed downstream of the fourth printhead along the machine direction. KCX-2148-PCT / 65125303PCT01

[0097] Nineteenth example embodiment: A method for printing on a web material, comprising: traversing web along a machine direction on a conveyer; applying ink from a first printhead and a second printhead onto the web, the second printhead spaced from the first printhead along the machine direction; and drawing air away from the web via a vacuum port disposed between the first and second printheads along the machine direction.

[0098] Twentieth example embodiment, the method of the nineteenth example embodiment, wherein the vacuum port draws dust away from the first and second printheads.

Claims

KCX-2148-PCT / 65125303PCT01What Is Claimed:1 . A printer for web material, comprising: a conveyer configured for traversing a web along a machine direction; a first printhead; a second printhead spaced from the first printhead along the machine direction; and a vacuum port disposed between the first and second printheads along the machine direction.

2. The printer of claim 1, wherein: the conveyer comprises a belt spaced from the first and second printheads by a gap along a transverse direction that is perpendicular to the machine direction; and the vacuum port is configured for drawing air away from the gap.

3. The printer of claim 2, wherein the gap is no greater than eight millimeters.

4. The printer of claim 1 , wherein the first printhead comprises a plurality of ink orifices spaced apart along a cross direction on the first printhead.

5. The printer of claim 1, further comprising a third printhead positioned adjacent the first printhead, the third printhead partially offset from the first printhead along a cross direction.

6. The printer of claim 1 , wherein a width of the vacuum port along a cross direction is greater than a width of the first printhead along the cross direction.

7. The printer of claim 1, wherein: the vacuum port has a depth along the machine direction and a width along a cross direction; and the width of the vacuum port is no less than twice the depth of the vacuum port.

8. The printer of claim 1 , wherein the vacuum port is configured for drawing air away from a gap between the vacuum port and the conveyer.

9. The printer of claim 1 , further comprising one or both of:KCX-2148-PCT / 65125303PCT01 an upstream vacuum chute disposed upstream of the first printhead along the machine direction; and a downstream vacuum chute disposed downstream of the second printhead along the machine direction.

10. The printer of claim 1 , further comprising a frame for supporting the first and second printheads over the conveyer, wherein the frame is spaced from ink orifices of the first and second printheads along a transverse direction.

11. A printer for web material, comprising: a conveyer configured for traversing a web along a machine direction; a first printhead; a second printhead positioned adjacent the first printhead, the second printhead partially offset from the first printhead along a cross direction that is perpendicular to the machine direction; a third printhead spaced from the first and second printheads along the machine direction; a fourth printhead positioned adjacent the third printhead, the fourth printhead partially offset from the third printhead along the cross direction; and a vacuum port disposed between the second and third printheads along the machine direction.

12. The printer of claim 11 , wherein: the conveyer comprises a belt spaced from the first and third printheads by a gap along a transverse direction that is perpendicular to the machine and cross directions; and the vacuum port is configured for drawing air away from the gap.

13. The printer of claim 12, wherein the gap is no greater than eight millimeters.

14. The printer of claim 11 , wherein the first printhead comprises a plurality of ink orifices spaced apart along the cross direction on the first printhead.

15. The printer of claim 11 , wherein a width of the vacuum port along the cross direction is greater than a collective width of the first and second printheads along the cross direction.

16. The printer of claim 11 , wherein:KCX-2148-PCT / 65125303PCT01 the vacuum port has a depth along the machine direction and a width along the cross direction; and the width of the vacuum port is no less than twice the depth of the vacuum port.

17. The printer of claim 11 , wherein the vacuum port is configured for drawing air away from a gap between the vacuum port and the conveyer.

18. The printer of claim 11 , further comprising one or both of: an upstream vacuum chute disposed upstream of the first printhead along the machine direction; and a downstream vacuum chute disposed downstream of the fourth printhead along the machine direction.

19. A method for printing on a web material, comprising: traversing web along a machine direction on a conveyer; applying ink from a first printhead and a second printhead onto the web, the second printhead spaced from the first printhead along the machine direction; and drawing air away from the web via a vacuum port disposed between the first and second printheads along the machine direction.

20. The method of claim 19, wherein the vacuum port draws dust away from the first and second printheads.

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