Carousel Container Printing System with Direct Transfer
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Solution Overview
Problem
Current printing systems for containers, such as bottles, face challenges in achieving high printing output with reliable function and high print quality, especially when dealing with materials like metals, glass, or plastic that require UV or electron beam curing, which complicates ink drying and cross-linking, and are prone to accuracy issues due to mechanical stresses and temperature fluctuations.
Innovation Solution
The system consists of at least two printing presses designed as carousels in series, with containers transferred directly between them, eliminating the need for transfer stars and allowing for tolerance compensation, and features a centralized ink supply system with individual pumps for each print head, ensuring consistent ink pressure and reducing centrifugal forces. Additionally, the system includes a cleaning device and operates all carousels at a synchronized speed to maintain consistent treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If containers are transported through multiple carousels arranged one behind the other with separate drying/crosslinking between each color, then UV-curing inks can be properly cured, but the machine length increases and complexity increases
Solution Approach 1:
The patent combines multiple printing and curing operations into a single carousel by integrating UV irradiation devices at printing stations within the same rotating carrier. This allows containers to receive multiple colors and UV curing in one continuous rotation, eliminating the need for separate carousels and transfer mechanisms, thus reducing machine length and complexity while maintaining reliable ink curing.
2Manufacturing precision
If containers are clamped in holders with high precision centering requirements to achieve 600 dpi print quality, then print accuracy is improved, but mechanical wear increases and reliability decreases at high production rates
Solution Approach 1:
The patent employs dynamic correction mechanisms including sensors that detect container position and orientation in real-time, with electric drives that actively adjust print head positioning to compensate for tolerances. This dynamic approach maintains high print quality without requiring extremely precise mechanical centering, thereby reducing wear on mechanical components and improving system reliability at high production rates.
3Productivity
If containers are transported at high speed (approx. 1.5 m/sec) to achieve high productivity, then production output increases, but ink droplet quality deteriorates due to airflow exposure
Solution Approach 1:
The patent implements continuous printing and curing operations within the rotating carousel system, where containers remain in a controlled environment throughout the printing and UV curing process. The continuous rotation at optimized speeds minimizes exposure to external airflow, maintaining ink droplet quality and print precision while achieving high productivity through uninterrupted processing.
4Adaptability or versatility
If multiple print heads are arranged in series to print multiple colors, then color printing capability is improved, but the distance between print dots becomes uneven and machine complexity increases
Solution Approach 1:
The patent combines multiple print heads for different colors into a single carousel structure, where all print heads are positioned on the same rotating carrier. This integration ensures that all print heads move together at the same speed and position, maintaining even spacing between print dots across all colors while providing full-color printing capability.
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 configuration reduces machinery complexity, maintains high print quality, and ensures consistent ink supply and pressure, enhancing the reliability and efficiency of the printing process, even at high production rates like 36,000 bottles per hour, by compensating for mechanical stresses and ensuring uniform treatment of containers.
Implementation Method 1
a liquid printing color (ink) that can be dried and/or crosslinked with heat can advantageously be used for printing
Implementation Method 2
While this is practicable for absorbent packaging materials. For other materials, such as metals, glass or plastic, the ink must either be dried by heat or cured by cross-linking with UV or electron beams
Implementation Method 3
the ink must either be dried by heat or cured by cross-linking with UV or electron beams
Implementation Method 4
the ink must either be dried by heat or cured by cross-linking with UV or electron beams
Data Source
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AI summary
The invention relates to a system for imprinting containers (B), such as bottles, with at least one printed image on at least one printing press (1) having at least one print head (11), wherein at least two printing presses (1) connected in series are designed as carousels for successively receiving the containers (B) to be imprinted and the containers (B) are transferred or taken from one carousel directly to a succeeding carousel.