Digital Printing Ink Application Units With Temperature Gradients
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Solution Overview
Problem
Existing digital printing technologies face challenges in maintaining print quality and reproducibility on non-paper objects due to condensation buildup on ink application units, leading to nozzle clogging, increased cleaning costs, and production downtime.
Innovation Solution
A digital printing facility with temperature control devices and electrical control units to manage ink application unit temperatures, ensuring a temperature gradient of at least 0.5°C to 1.5°C between neighboring units, and incorporating air flow deflectors and suction devices to prevent condensation buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If digital printing facilities are used to print on non-paper objects, then print quality and reproducibility can be improved, but condensation buildup on ink application units occurs leading to nozzle clogging and increased cleaning costs
Solution Approach 1:
The patent applies parameter changes by controlling the temperature of ink application units to prevent condensation. Specifically, the temperature is maintained within a range of 10°C to 30°C, which prevents the air around the ink application units from reaching dew point and forming condensation. This temperature control directly addresses the harmful condensation effect while maintaining print quality.
Solution Approach 2:
The patent converts the harmful condensation effect into a beneficial temperature control strategy. By monitoring and controlling the temperature of ink application units, the system prevents condensation formation while also ensuring optimal ink viscosity and transfer characteristics. The temperature control system uses heating elements and cooling mechanisms to maintain the desired temperature range, effectively converting a potential problem into a controlled parameter that ensures both print quality and operational reliability.
2Reliability
If cleaning efforts are increased to remove condensation, then nozzle clogging can be prevented, but production costs increase due to cleaning liquids and ink expenditure
Solution Approach 1:
The patent applies preliminary action by controlling the temperature of ink application units before condensation can form. The temperature control system proactively maintains the temperature within the 10°C to 30°C range, preventing the conditions that lead to condensation. This preventive approach eliminates the need for subsequent cleaning operations, thereby preventing loss of cleaning liquids and printing ink while ensuring continuous nozzle functionality.
Solution Approach 2:
The temperature control system enables the ink application units to self-regulate their operating conditions to prevent condensation. By maintaining optimal temperature, the system prevents the formation of harmful condensation without requiring external cleaning interventions. This self-service approach reduces dependency on cleaning operations and associated material consumption.
3Manufacturing precision
If cleaning operations are performed frequently, then print quality can be maintained, but production downtime increases
Solution Approach 1:
The patent applies preliminary action by implementing temperature control that prevents condensation formation before it can affect print quality or require cleaning. The temperature is maintained within 10°C to 30°C, which prevents the air around ink application units from reaching dew point. This preventive measure ensures consistent print quality over extended periods without requiring production-stopping cleaning operations.
Solution Approach 2:
The temperature control system enables continuous operation of the digital printing facility by preventing condensation that would otherwise require cleaning interruptions. The heating and cooling mechanisms maintain optimal temperature continuously, ensuring that ink application units remain free of condensation and operational without downtime for cleaning maintenance.
4Productivity
If temperature control is implemented to prevent condensation, then cleaning needs are reduced, but device complexity increases
Solution Approach 1:
The patent applies parameter changes by introducing temperature control as a new parameter to manage condensation. The system monitors and adjusts the temperature of ink application units within a specific range (10°C to 30°C). While this adds temperature control components, the benefits of continuous printing capability and elimination of cleaning operations significantly improve productivity, justifying the increased device complexity.
Solution Approach 2:
The patent replaces the mechanical cleaning system with a thermal control system. Instead of using mechanical cleaning devices that require disassembly, cleaning solutions, and manual intervention, the system uses heating and cooling mechanisms to prevent condensation formation. This substitution reduces mechanical complexity in the long run by eliminating the need for cleaning mechanisms while maintaining or improving printing reliability.
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
Reduces condensation on ink application units, minimizing nozzle clogging and cleaning needs, thereby ensuring continuous and high-quality printing with reduced production costs and downtime.
Implementation Method 1
the temperatures of the ink application units increase in the feed direction and the temperatures of two neighbouring ink application units differ by at least 0.5° C. and at most 1.5° C.
Implementation Method 2
it is known that a build-up of condensation on the print head may occur. This has a negative impact on the quality of the print results.
Data Source
AI summary
The disclosure relates to a method for printing an object, which is not a paper, by a digital printing system which has a plurality of ink application units for applying printing ink of different colours, in which method an ink carrier element is guided past the ink application units in a feed direction. The digital printing system has a device which is designed and suitable for preventing or reducing the formation of condensation on the ink application units, and this device is used to prevent or reduce the formation of condensation on the ink application units. The device has a temperature-control device and an electrical controller, wherein the temperature-control device is designed to influence a temperature of the ink application units. The electrical controller is designed to control the temperature-control device in such a way that the ink application units have different temperatures, wherein the temperatures of the ink application units increase in the feed direction and the temperatures of two adjacent ink application units differ by at least 0.5° C. and by at most 1.5° C. The temperatures of the first ink application unit in the feed direction and of the last ink application unit in the feed direction differ by at most 10° C.