Angular Print Head Arrays for Seamless Trim Surface Printing
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Solution Overview
Problem
Existing trim pieces for flooring installations lack efficient and precise methods for printing decorative patterns and textures directly onto curved or complex surfaces, leading to visible seams and alignment issues.
Innovation Solution
A system comprising a conveyor and multiple print head arrays with angularly offset print heads, capable of simultaneously printing on both flat and curved portions of a substrate, utilizing precise nozzle control and UV curing, along with embossing and coating processes to achieve seamless and high-quality decorative finishes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional printing methods are used on trim pieces with curved or complex surfaces, then printing can be performed, but visible seams and alignment issues occur
Solution Approach 1:
The printing system is divided into multiple independently controllable print heads arranged in arrays. Each print head can be precisely positioned and angled to print on specific portions of the substrate surface, allowing seamless coverage across curved and complex geometries without visible seams
Solution Approach 2:
The print heads are oriented at angular offsets relative to the substrate movement axis, transitioning from traditional single-plane printing to multi-dimensional angular positioning. This enables simultaneous printing on both flat and curved surface portions while maintaining precise alignment and eliminating visible seams
2Adaptability or versatility
If multiple print heads are used to print on complex surfaces, then printing coverage is improved, but system complexity increases
Solution Approach 1:
The print head arrays are designed with multiple print heads that can be selectively activated and positioned to handle various substrate geometries. The same array configuration can print on flat surfaces, curved surfaces, and complex three-dimensional shapes, providing universal adaptability across different trim piece geometries
Solution Approach 2:
The print heads are mounted on a system that allows dynamic adjustment of their positions and angles relative to the substrate movement axis. This dynamic positioning capability enables the print heads to adapt to different surface geometries while maintaining precise printing alignment, managing system complexity through controlled flexibility
3Ease of manufacture
If printing is performed on curved surfaces, then decorative patterns can be applied, but alignment precision is reduced
Solution Approach 1:
Each print head in the array is independently positioned and angled to match the local surface geometry at its specific location. This local optimization ensures that each print head maintains precise alignment with its corresponding substrate portion, whether flat or curved, while collectively enabling comprehensive decorative pattern application across the entire surface
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-precision, single-pass printing on flexible substrates like trim pieces, ensuring seamless alignment and accurate deposition of ink and textures without visible seams, enhancing aesthetic and functional qualities.
Implementation Method 1
utilizing precise nozzle control and UV curing
Data Source
AI summary
A system for printing on a substrate can comprise a conveyor that is configured to move the substrate along a substrate movement axis. The system can further comprise at least one print head array. Each print head array has a plurality of print heads, each print head having a respective orientation axis. The plurality of print heads can have at least a first print head and a second print head, wherein the orientation axis of the first print head is angularly offset from the orientation axis of the second print head. The first print head can be offset from the second print head along the substrate movement axis.