Digital Printing on Curved Plastic Containers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional techniques for printing on curved plastic containers face challenges such as improper color registration and high costs associated with changing images or designs, with inkjet printing on curved surfaces being particularly difficult.
Innovation Solution
A method for printing digital images on curved plastic containers involves holding the containers under internal pressure and using a conveyer system with synchronized top and base holders to maintain consistent velocity and position, allowing for simultaneous printing on multiple areas with inkjet technology and UV-reactive ink, followed by curing, while using pre-treatment to enhance ink adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional printing techniques are used on curved plastic containers, then printing can be performed, but proper registration between colors is difficult to obtain
Solution Approach 1:
The patent replaces conventional mechanical printing systems with digital printing technology. The digital printing system uses a digital image processor to directly control print heads, eliminating the mechanical registration issues inherent in conventional multi-color printing processes. This substitution of mechanical systems with digital control achieves precise color registration without the complexity of mechanical alignment mechanisms.
2Adaptability or versatility
If conventional printing techniques are used on curved plastic containers, then printing can be performed, but changing images, designs or wording is expensive and time consuming
Solution Approach 1:
The patent employs digital storage of image data instead of physical printing plates or screens. Different images, designs, or wording can be retrieved from digital storage and printed by simply loading new digital data, eliminating the need to manufacture new physical printing components. This digital copying approach enables rapid design changes without time loss or additional manufacturing costs.
3Productivity
If inkjet printing with multiple nozzles is used, then printing on flat surfaces is effective, but satisfactory printing on curved surfaces is difficult
Solution Approach 1:
The patent makes the printing system dynamic by allowing the print heads to move independently and adjust their positions relative to the curved container surface. The system can dynamically adapt to the curvature by varying the angle and distance of each nozzle, maintaining consistent ink deposition quality across curved surfaces while preserving high printing speed through coordinated motion control.
4Manufacturing precision
If digital printing is performed on curved plastic containers, then full color digital graphic images can be printed, but maintaining consistent velocity and position during printing is challenging
Solution Approach 1:
The patent implements a feedback control system where sensors continuously monitor the position and velocity of containers on the conveyer system. This real-time feedback information is used to adjust the printing parameters and container feed rate, ensuring consistent velocity and position during the printing process. The feedback loop compensates for variations in container speed or position, maintaining precise image registration despite the complexity of the conveyer system.
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
Enables efficient, high-quality, full-color digital printing on both sides of curved plastic containers at a reasonable speed and cost, ensuring proper registration and efficient ink adhesion.
Implementation Method 1
The ink may be a UV-reactive ink, in which case after printing the ink may be cured by exposure to UV light.
Implementation Method 2
One may also, for example, treat the container surface to be printed prior to the printing operation, as by flame treatment, corona treatment or plasma jet treatment.
Implementation Method 3
One may also, for example, treat the container surface to be printed prior to the printing operation, as by flame treatment, corona treatment or plasma jet treatment.
Implementation Method 4
One may also, for example, treat the container surface to be printed prior to the printing operation, as by flame treatment, corona treatment or plasma jet treatment.
Data Source
AI summary
A method for printing digital images on plastic containers having curved surfaces, including providing a series of hollow plastic containers, moving the containers along a track past first and second digital printing locations, and printing first and second digital images on the curved container surfaces while maintaining the container being printed under internal pressure and while firmly holding the container being printed at spaced locations thereon.