Central Gravure Roll with Internal Ink Mixing for Color Gamut
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Solution Overview
Problem
Gravure printing systems require multiple stations and significant floor space to produce high-quality, multi-color images on web substrates, leading to increased costs and space requirements due to the need for individual gravure rolls and ancillary equipment.
Innovation Solution
A gravure printing system with a central roll featuring discrete cells that can receive a combination of primary fluids, allowing for the internal mixing of inks to create a single fluid that can be printed onto a web substrate, reducing the need for multiple stations and space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple individual gravure stations are used to print multiple colors on a web substrate, then the color gamut and print quality are improved, but the floor space and equipment costs increase significantly
Solution Approach 1:
The patent combines multiple gravure roll functions into a single central roll by integrating multiple ink supply systems and distribution manifolds within the same roll structure. This allows multiple colors to be applied simultaneously from one roll rather than requiring sequential passage through multiple separate gravure stations, thereby reducing floor space while maintaining color gamut capability
Solution Approach 2:
The central roll is designed to perform multiple functions simultaneously - it can supply multiple different inks (cyan, magenta, yellow, black, and spot colors) through a single roll structure. The roll acts as both a printing surface and an internal ink distribution system, eliminating the need for separate gravure rolls for each color station
2Manufacturing precision
If multiple individual gravure rolls are used for different inks, then each ink can be applied with precision, but the device complexity and equipment costs increase
Solution Approach 1:
The central roll is segmented into multiple independent ink supply zones, each with its own distribution manifold and cell structure. Each ink type (cyan, magenta, yellow, black, spot colors) has dedicated channels and cells within the same roll, allowing precise control of each ink's application while maintaining a unified roll structure that reduces overall device complexity
Solution Approach 2:
The patent introduces an internal ink distribution manifold system as an intermediary between the ink supply sources and the printing surface. This manifold system acts as a mediator that distributes different inks to their respective cells within the central roll, enabling precise ink application without requiring separate external delivery systems for each color
3Area of stationary object
If a single central roll with internal fluid mixing is used, then floor space and equipment costs are reduced, but the complexity of internal fluid management increases
Solution Approach 1:
The patent extracts the ink mixing and distribution functionality from external systems and embeds it directly within the central roll structure. The distribution manifolds and fluid channels are integrated into the roll itself, taking out the complexity from the external equipment and consolidating it within the roll's internal architecture, which reduces floor space while managing fluid complexity through centralized integration
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 solution enables the application of multiple inks on a single web substrate with a single gravure roll, significantly reducing the required floor space and equipment costs while maintaining high-quality print output.
Implementation Method 1
Each of the at least two primary fluids are placed in fluid contact at a first position internal to the central roll. The first combination of at least two primary fluids is fluidically displaceable into a first cell of the first plurality of discrete cells from a second position internal to the central roll.
Implementation Method 2
The capillary action of the substrate and the pressure from the impression rollers draw and/or force the ink out of the cell cavity of the gravure roll and transfer it to the substrate
Data Source
AI summary
A gravure printing system is disclosed. The gravure printing system is provided with a central roll having a first plurality of discrete cells disposed upon an outer surface thereof. Each cell of the first plurality of discrete cells is capable of receiving a fluid that is a first combination of at least two primary fluids. Each of the at least two primary fluids are placed in fluid contact at a first position internal to the central roll. The first combination of at least two primary fluids is fluidically displaceable into a first cell of the first plurality of discrete cells from a second position internal to the central roll.