Alignment Cylinder Printing Unit for Magnetic Coating Curing
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Solution Overview
Problem
Existing printing technologies lack a comprehensive solution for applying coating materials with magnetic or magnetizable particles to substrates, aligning them, and curing them with high resolution and simplicity, while allowing for image information to be incorporated without impacting color properties.
Innovation Solution
A printing unit with a first alignment cylinder, non-impact printing point, and curing device, where the transport path is defined by the alignment cylinder, allowing for the application of coating materials with alignable particles, selective curing, and incorporation of image information using printheads, with a colorless additive to modify curing properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If coating material with magnetic particles is applied and aligned using conventional methods, then alignment can be achieved, but the process complexity increases and resolution is limited
Solution Approach 1:
The patent combines the alignment device and curing device into a single integrated printing unit that processes coating material with magnetic particles in one continuous operation. The alignment cylinder and curing element work together within the same device architecture, eliminating the need for separate alignment and curing stations, thereby reducing overall system complexity while maintaining high alignment precision
Solution Approach 2:
The printing unit is designed as a multi-functional system that performs coating application, magnetic particle alignment, and curing operations within a single device. The transport path is universally designed to accommodate all these functions sequentially, allowing one device to replace multiple specialized machines and simplifying the overall process
2Manufacturing precision
If conventional printing methods are used to apply coating material, then application can be achieved, but image resolution and color properties are compromised
Solution Approach 1:
The patent replaces conventional mechanical contact printing methods with a non-contact inkjet printing system for applying the coating material. The inkjet printhead deposits material precisely without mechanical contact, enabling high image resolution and maintaining color properties while simplifying the manufacturing process through digital control
Solution Approach 2:
The system controls the coating material application by changing parameters such as droplet size, deposition speed, and material composition to achieve high resolution images. The magnetic particle concentration and coating thickness are precisely controlled parameters that enable both high image quality and simplified processing
3Productivity
If multiple processing steps are used for coating and alignment, then processing can be achieved, but space utilization and time are increased
Solution Approach 1:
The patent merges multiple processing steps (coating application, alignment, and curing) into a single integrated printing unit. The coating material is applied, aligned, and cured in continuous sequence within one device, eliminating the need for multiple separate processing units and reducing overall space requirements
Solution Approach 2:
The printing unit operates continuously without interruption, performing coating application, alignment, and curing in a seamless sequence. The transport path enables continuous movement of the substrate through all processing stages, eliminating idle time between operations and maximizing productivity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables high-resolution, simple incorporation of image information into coating materials, creating thick layers with visible effects, and allows for multiple image areas with different pigment orientations, while maintaining color neutrality and efficient use of space.
Implementation Method 1
a first alignment cylinder (709) along a transport path provided for the transport of substrate (02) after the first form-bound printing point (758)... these particles are oriented parallel to each other by means of an alignment device
Implementation Method 2
the layer of the coating material is then crosslinked by means of radiation... at least one first curing device (772) with a first curing area (788) assigned to it along the transport path
Data Source
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AI summary
The invention relates to a printing unit (700), which has a first impact printing position (758) formed by a pair of interacting rotational bodies (708; 752), wherein: downstream of the first impact printing position (758) along a transport path, the printing unit (700) has a first alignment cylinder (709) and a first non-impact printing position (758), with which first non-impact printing position at least one printhead (791) is associated; downstream of the first non-impact printing position (758) along the transport path, the printing unit (700) has a first curing device (772) with a first curing region (788) associated therewith; downstream of the at least one first alignment cylinder (709), the printing unit (700) has at least one second alignment cylinder (709); downstream of the first alignment cylinder (709), the printing unit (700) has a second non-impact printing position (758), with which a second printhead (791) is associated; and, downstream of the second non-impact printing position (758), the printing unit (700) has a second curing device (772) with a second curing region (788) associated therewith.