Digital Printing Transfer Blanket for Metallic Container Decoration
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Solution Overview
Problem
Existing methods for decorating metallic containers at high speeds often compromise on image quality or production efficiency, as they struggle to maintain high-definition printing while meeting the rapid production demands of beverage container manufacturing lines.
Innovation Solution
A digital printing system utilizing a transfer blanket to apply decorations, where inkjet or electrophotographic digital print units form images on the blanket, which are then transferred to the container, allowing for adjustable ink viscosity and temperature control to ensure high-quality, high-speed decoration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If digital printing is used to form decoration on transfer blanket, then manufacturing precision and image quality are improved, but device complexity increases
Solution Approach 1:
The patent introduces a transfer blanket as an intermediary medium between the digital print unit and the metallic container. The digital print unit forms the decoration on the transfer blanket, which then contacts the container to transfer the decoration. This intermediary approach enables high-definition printing while simplifying the overall decoration process compared to direct high-speed printing on the moving container.
2Productivity
If high-speed printing is implemented to meet production demands, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The decoration process is segmented into distinct stages: (1) forming the decoration on the transfer blanket using a digital print unit, (2) contacting the transfer blanket with the metallic container, and (3) transferring the decoration to the container. This segmentation allows the printing stage to operate at optimal speed for high-definition quality while the transfer stage handles the high-speed production requirements, thereby resolving the contradiction between productivity and manufacturing precision.
3Device complexity
If conventional printing methods are used, then device complexity is reduced, but productivity decreases due to equipment changeovers
Solution Approach 1:
The patent employs parameter changes in the form of temperature control and viscosity adjustment of the decorating material. By controlling the temperature and viscosity, the system optimizes the transfer characteristics of the decoration from the blanket to the container. This enables consistent high-quality transfer across different production conditions and minimizes equipment changeovers, thereby improving productivity without significantly increasing device complexity.
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 cost-effective, fast, and reliable decoration of metallic containers with high-definition images at speeds required for beverage production lines, minimizing equipment changeovers and downtime, and accommodating small batch variations.
Implementation Method 1
In one embodiment, the digital print unit includes an inkjet print head which conveys the decorating material to the transfer blanket
Implementation Method 2
In another embodiment, the digital print unit is an electrophotographic system which conveys toner to the transfer blanket to form the decoration
Implementation Method 3
The transfer blanket then contacts an exterior surface portion of a metallic container and the decoration is transferred to the exterior surface of the metallic container
Implementation Method 4
The decorator can include a temperature control device configured to adjust a temperature of the transfer blanket
Data Source
Figure 1
Figure 1A
Figure 1B
AI summary
Apparatus and methods are provided for decorating a metallic container with an image or indicia on a predetermined portion of an outer surface of a container body. The decorator includes at least one digital print unit, a transfer blanket, and a support element. The digital print unit transfers a decorating material to the transfer blanket to form a decoration on the transfer blanket. The support element then moves a metallic container into contact with the transfer blanket to transfer the decorating material to an exterior surface portion of the metallic container to decorate the metallic container. In one embodiment, the digital print unit is an electrophotographic system which transfers a toner material to the transfer blanket. In another embodiment, the digital print unit includes an inkjet print head which transfers an ink to the transfer blanket. Optionally, the decorator can include two or more support elements.