Corrugated Board Drying Control for Print Quality

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Solution Overview

Problem

The production of corrugated board faces challenges with ink trapping and drying, leading to patchy print areas or agglomerations, especially when untreated webs are used, and rapid drying is necessary to prevent droplet formation, while maintaining high print quality and efficiency across varying material web conveying speeds.

Innovation Solution

The solution involves controlling the start of drying by adjusting the print area drying arrangement, allowing for constant print quality across different conveying speeds by delaying or advancing the drying process based on web speed, using a combination of pre-drying and drying devices with adjustable positions and capacities, and incorporating temperature sensors for precise control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of time

If rapid drying is applied to untreated webs of material, then ink trapping time is reduced, but patchy print areas and poor print quality occur

Engineering Contradiction:
Improveink trapping timeVSAvoidprint quality
Core Design Contradiction:
Loss of timeVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by introducing a drying arrangement that activates before the printing process. The material web is pre-dried in a controlled manner before ink application, creating optimal surface conditions for ink trapping. This preliminary drying prevents the material from being too wet during printing, thereby avoiding patchy print areas while maintaining efficient overall processing time.

Inventive Principle:
Principle #10Preliminary action

2Productivity

If material web conveying speed is increased, then productivity is improved, but ink trapping becomes insufficient leading to poor print quality

Engineering Contradiction:
Improveconveying speedVSAvoidprint quality
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

The patent implements dynamics by making the drying arrangement adjustable and adaptable to different conveying speeds. The system can dynamically modify drying parameters such as drying time, temperature, and intensity based on the actual conveying speed. This dynamic adjustment ensures optimal ink trapping conditions are maintained regardless of whether the web is conveyed at high or low speeds, thereby resolving the contradiction between productivity and print quality.

Inventive Principle:
Principle #15Dynamics

3Manufacturing precision

If drying is delayed to improve ink trapping, then print quality is improved, but production time increases

Engineering Contradiction:
Improveprint qualityVSAvoidproduction time
Core Design Contradiction:
Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent applies parameter changes by systematically adjusting multiple drying parameters including temperature, humidity, and drying duration. Rather than simply delaying drying, the system optimizes these parameters to achieve effective ink trapping in a condensed time frame. The drying arrangement can vary temperature profiles and drying intensity to maximize ink absorption efficiency, thereby improving print quality without proportionally increasing production time.

Inventive Principle:
Principle #35Parameter changes

4Manufacturing precision

If drying is accelerated to prevent droplet agglomerations, then print quality is improved, but ink trapping time is insufficient

Engineering Contradiction:
Improveprint qualityVSAvoidink trapping time
Core Design Contradiction:
Manufacturing precisionVSDuration of action of moving object

Solution Approach 1:

The patent implements segmentation by dividing the drying process into distinct stages or zones. The drying arrangement can apply different drying intensities at different locations along the material web path. This segmented approach allows certain areas to receive intensified drying to prevent droplet agglomerations, while other areas maintain longer exposure times for adequate ink trapping, thereby resolving the contradiction between preventing agglomerations and allowing sufficient ink trapping time.

Inventive Principle:
Principle #1Segmentation

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 ensures consistent print quality and stability of ink trapping across varying conveying speeds, preventing excessive dot gain and flow, while maintaining efficient drying and preventing web distortion, thus enhancing the overall print quality and economic viability of the process.

Implementation Method 1

a drying arrangement (40) for drying the at least one print area (39) of the printed material web (36)

Methodology Applied
Scientific EffectEvaporation: Evaporation

Implementation Method 2

incorporating temperature sensors for precise control

Methodology Applied
Scientific EffectTemperature detection:

Data Source

PatentEP3150378B1Assembly and method for the production of corrugated cardboard
Publication Date: 2018.06.13 BHS CORRUGATED MACHINEN UND ANLANGENBAU GMBH
  • EP3150378B1 patent drawingFigure 1
  • EP3150378B1 patent drawingFigure 2
  • EP3150378B1 patent drawingFigure 3

AI summary

A corrugated board plant for the production of corrugated board comprises a material web discharge device (30) for discharging a material web (36), a conveying device for conveying the material web (36) along a material web conveying path (44), a printing device (37) downstream of the material web discharge device (30) for creating at least one printed area on the material web (36), a printed area drying arrangement (40) downstream of the printing device (37) for drying the at least one printed area, and a joining device (70) downstream of the printed area drying arrangement (40) for joining the printed material web (36) with at least one further material web (22) to produce a corrugated board web (75) laminated on at least one side. The start of the drying process for the at least one printed area applied to the material web (36) can be controlled by the printed area drying arrangement (40).