Adaptive Inkjet Printing for Corrugated Media Deformation
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Solution Overview
Problem
Printing on corrugated media can result in non-uniform application of printing fluid due to deformation, leading to undesirable visual effects such as lines and changes in gloss or color hue, as existing systems fail to adapt to the media's irregular shape during the printing process.
Innovation Solution
A printing system that includes an array of nozzles and a print controller, which determines the deformation of the corrugated media using sensors and adjusts control parameters such as nozzle angle, distance, spray angle, and flow intensity to ensure uniform application of printing fluid, regardless of the media's shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a roller coated in printing fluid is directly applied to printed media, then the printing fluid can be applied to the media surface, but non-uniform application occurs due to corrugated media deformation causing lines and gloss variations
Solution Approach 1:
The patent replaces the mechanical roller coating system with a non-contact inkjet printing system. Instead of using a physical roller that contacts the media surface, the invention uses print heads with nozzles that deposit printing fluid droplets in mid-air, which are then transferred to the media. This eliminates the problem of non-uniform application caused by media deformation since there is no mechanical contact between the coating device and the corrugated surface.
Solution Approach 2:
The patent implements dynamic control of the inkjet printing process by adjusting print head position, nozzle orientation, and droplet ejection timing based on real-time detection of media deformation. Sensors detect the actual surface topology of the corrugated media, and this information feeds back to control the printing parameters, allowing the system to adapt dynamically to varying media shapes and maintain uniform printing fluid application.
2Ease of manufacture
If printing fluid is applied to deformed corrugated media without adjustment, then the process is simple, but undesirable visual effects such as lines and color hue changes occur
Solution Approach 1:
The patent incorporates a feedback control system where sensors detect the actual position and deformation of the corrugated media surface during the printing process. This detection information is fed back to the control system, which adjusts printing parameters such as droplet size, ejection timing, and print head positioning to compensate for media deformation, thereby maintaining high visual quality without complicating the manufacturing process.
Solution Approach 2:
The system performs self-adjustment by automatically detecting media deformation and correcting printing parameters without requiring manual intervention or complex setup procedures. The integrated sensors and control system enable the printing process to self-correct for various media shapes and conditions, maintaining high quality output while keeping the operation simple.
3Device complexity
If a roller coating system is used for applying printing fluid, then the equipment structure is simple, but it cannot adapt to irregular media shapes causing non-uniform coating
Solution Approach 1:
The patent replaces the simple but inflexible mechanical roller coating system with an inkjet printing system that offers superior adaptability. While inkjet printers are more complex than rollers, they provide non-contact deposition capability that can easily adapt to irregular media shapes, creases, and deformations without requiring complex mechanical adjustments or specialized roller designs.
Solution Approach 2:
The inkjet printing system employs dynamic control mechanisms that allow real-time adjustment of printing parameters in response to media deformation. This dynamic capability enables the system to maintain adaptability to irregular media shapes without requiring complex mechanical structures, as the adaptation is achieved through controlled droplet ejection rather than mechanical conformity.
Data Source
Figure 1
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Figure 4A~4C
AI summary
A method of depositing printing fluid on a sheet of corrugated media (106) comprises determining a deformation of a sheet of corrugated media, adjusting control parameters for a plurality of nozzles (104) based on the determined deformation, and depositing printing fluid from the plurality of nozzles onto the sheet of corrugated media according to the adjusted control parameters.