Autosplicer for Continuous Inkjet Roll Exchange
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Solution Overview
Problem
High-capacity inkjet printers face downtime and print quality issues due to rapid drying of print heads during substrate roll exchanges, especially in warm climates, leading to nozzle clogging and increased costs from cleaning processes.
Innovation Solution
Implementing an on-the-fly roll exchange method using an autosplicer that continues ink ejection from nozzles during roll changes, printing predetermined patterns to prevent drying, and maintaining print head clearance to avoid damage, allowing uninterrupted printing and reducing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If printing is stopped during roll exchange, then the exchange can be performed, but the print head dries up quickly leading to nozzle clogging
Solution Approach 1:
The patent applies continuity of useful action by maintaining ink ejection from the nozzles during the entire roll exchange process. The printing process continues without interruption, with ink being ejected onto the substrate throughout the exchange, preventing the nozzles from drying up while allowing the rolls to be exchanged.
Solution Approach 2:
The patent applies preliminary action by positioning the second printing substrate web in advance and preparing the autosplicer to join it to the first web before the exchange is complete. This allows the printing process to continue seamlessly without stopping, as the substrate is already prepared and positioned for continuous ink ejection.
2Reliability
If a cleaning process is executed after roll exchange, then dried ink is removed, but additional cost and downtime are incurred
Solution Approach 1:
The patent eliminates the need for cleaning processes by maintaining continuous ink ejection during roll exchange. Since the nozzles never stop ejecting ink, no dried ink accumulates on the nozzles, making cleaning unnecessary and thereby eliminating the associated downtime and costs.
Solution Approach 2:
The patent converts the potentially harmful effect of continuous ink ejection (which would normally waste ink) into a benefit by using it to prevent nozzle drying during exchange. The continuous ink flow that would seem wasteful actually serves the dual purpose of preventing clogging while the exchange occurs.
3Productivity
If roll exchange is performed on-the-fly, then printing continues without stopping, but the two printing substrate webs must be glued together in the transition region
Solution Approach 1:
The patent uses an autosplicer as an intermediary device that joins the first and second printing substrate webs together. This intermediary mechanism allows the continuous printing process to proceed without interruption by seamlessly connecting the two rolls, enabling on-the-fly exchange while maintaining 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
This approach minimizes printer downtime, eliminates the need for pre-exchange cleaning, ensures high print quality, and maintains process speed by preventing ink drying and nozzle clogging during roll exchanges.
Implementation Method 1
ink is continued to be ejected without interruption from the nozzles of the print head during the exchange of the printing substrate rolls
Implementation Method 2
a second printing substrate web 24 is adjoined with the aid of an autosplicer 20 to a printing substrate web 14
Data Source
AI summary
Methods to exchange printing substrate rolls in a printer are described. In an exchange method, ink is printed to a first printing substrate web being unwound from a first printing substrate roll. The first printing substrate web is exchanged with a second printing substrate web being unwound from a second printing substrate roll. A transition region of the first and the second printing substrate webs is printed to during the exchange of the first and the second printing substrate webs. The transition region can be formed by gluing the second and the first printing substrate webs atop one another. A predetermined pattern can be printed onto the transition region during the exchange of the printing substrate rolls. The predetermined pattern can be chosen such that all nozzles of at least one print head are used for printing.