Bottle-Shaped Can Printing with Tone Chart Color Matching
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Solution Overview
Problem
Existing methods for decorating and printing on bottle-shaped cans result in color changes and inconsistencies due to severe processing, making it difficult to achieve desired color and design uniformity, especially in the thinned trunk portion.
Innovation Solution
A method involving multiple paint applications to match the ground color, preparing a tone chart based on color mixing, and determining the design color scheme considering the color changes post-forming, followed by restoring the color of non-printed areas to match the resin coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the metal sheet is coated with a colored resin layer in advance to decorate the bottle-shaped can, then the base color for decoration is provided, but the color of the coating layer lightens (fades) with the progress of drawing, making it difficult to print the design in the desired color
Solution Approach 1:
The patent applies preliminary coloring to the metal sheet before drawing, but anticipates the color fading that will occur during the drawing process. The coloring is performed in advance with the understanding that the color intensity will change, and this preliminary action sets the foundation for subsequent color correction.
Solution Approach 2:
The patent implements a feedback mechanism where the color of the coating layer is measured at different stages of the drawing process. This feedback information about color changes is used to adjust and correct the design color values, ensuring that the final printed design achieves the desired color appearance despite the fading that occurs during forming.
2Ease of manufacture
If the design is printed on the can trunk after forming, then the decoration is applied to the finished product, but the base color would be changed with the progress of processing, requiring multiple redesign and reprinting steps
Solution Approach 1:
The patent performs preliminary coloring of the metal sheet before the drawing process, establishing the base color in advance. This preliminary action allows for better control of the final appearance, as the color foundation is set before the forming operations that would otherwise cause unpredictable color changes.
Solution Approach 2:
The patent uses feedback from color measurements taken during the drawing process to calculate corrected design color values. This feedback loop eliminates the need for multiple trial printings and redesigns, as the design colors are pre-adjusted based on measured color changes, significantly reducing iteration time.
3Adaptability or versatility
If chromatic pigment is mixed into the adhesion layer to serve as a glossy metal base layer, then the color of the alloy sheet can be seen through the adhesion layer, but the bottle-shaped can may not be decorated in a colorful manner
Solution Approach 1:
The patent applies different colors of resin coating to different sections of the metal sheet before drawing. This local quality approach allows each region to have its own specific color characteristics, enabling diverse and colorful decoration schemes while maintaining control over the final appearance after drawing-induced color changes.
Solution Approach 2:
The patent changes the color parameters (hue, saturation, brightness) of the resin coating applied to the metal sheet based on the specific design requirements and the expected color fading during drawing. By adjusting these parameters in advance, the patent achieves versatile color decoration while compensating for the color changes that will occur during the forming process.
Data Source
AI summary
A manufacturing method of a bottle-shaped can includes forming a cylindrical can trunk by drawing or ironing a metal sheet coated with a colored resin and printing a design on the outer surface of the can trunk. The manufacturing method further includes painting a predetermined section of the outer surface of the can trunk multiple times while changing colors of inks thereby collecting samples of colors resulting from mixing the colors of the inks with a ground color of the predetermined section, preparing a tone chart by groups of hues of the colors having the same brightness and colorfulness, determining a color scheme of the design with reference to the tone chart, and printing the design on the predetermined section in the determined color scheme.