Inkjet Printing on Containers with Overlapping Partial Imprints
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Solution Overview
Problem
Inkjet printing on containers faces challenges with visible transitions and connection gaps between partial prints due to dimensional tolerances and the need for precise alignment of print heads, leading to poor-quality connecting areas.
Innovation Solution
A method where first and second partial imprints overlap and mesh in the connection area, forming an interlocking or mosaic-like connection that blurs the transition between image areas, reducing the requirements for dimensional accuracy and print head positioning, and allowing for continuous printing over the container's circumference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If partial imprints are printed to cover the entire container circumference, then complete printing coverage is achieved, but visible transitions and connection gaps appear between partial prints
Solution Approach 1:
The printing process is divided into multiple partial imprints that are printed sequentially by different print heads or by the same print head at different positions. Each partial imprint covers a specific circumferential section of the container, allowing the entire circumference to be covered while managing the complexity of connection areas between segments.
Solution Approach 2:
Overlapping print areas are designed in advance between adjacent partial imprints. The connection areas are pre-planned to overlap, and the ink distribution in these overlapping regions is adjusted beforehand to ensure seamless blending. This preliminary design of overlap regions prevents visible transitions and connection gaps before the actual printing occurs.
2Manufacturing precision
If print heads are positioned precisely to avoid overlapping, then manufacturing accuracy is maintained, but connection gaps appear between partial prints
Solution Approach 1:
Adjacent partial imprints are designed to overlap in connection areas, merging the print outputs from different print heads or different positions. This merging approach ensures that even if there are positioning variations, the overlapping ink deposits blend together to form a continuous printed image without gaps, thereby maintaining print image continuity.
Solution Approach 2:
The ink distribution parameters in overlapping connection areas are modified to facilitate seamless blending. By adjusting the ink density, droplet size, or deposition timing in the overlap regions, the transition between partial imprints becomes imperceptible, ensuring continuity even with moderate positioning tolerances.
3Reliability
If print heads overlap to disguise connection gaps, then print image continuity is improved, but alignment requirements become more stringent
Solution Approach 1:
The overlapping connection areas act as a cushioning zone that compensates for alignment variations between print heads. By designing sufficient overlap margins beforehand, the system creates a buffer region where positioning inaccuracies can be absorbed without affecting the overall print quality or creating visible gaps, thereby reducing the stringency of alignment requirements.
4Productivity
If containers are transported at high speeds for productivity, then production efficiency is improved, but positioning and printing continuity become more difficult
Solution Approach 1:
The printing process is designed to operate continuously during container transport without interruption. Multiple print heads are positioned along the transport path to print different sections of the container simultaneously or sequentially during its passage, maintaining continuous printing action even at high transport speeds. This eliminates the need for stopping or slowing down the container to complete the printing process.
Solution Approach 2:
The container surface is divided into multiple sections that can be printed by different print heads during a single pass. This segmentation allows the printing task to be distributed across multiple stationary print heads, enabling continuous high-speed printing as the container moves through the printing station without requiring precise positioning for each complete print cycle.
Data Source
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AI summary
A method and a device for inkjet printing on containers are described. According to the invention, at least a first and a second partial print are joined together in the printing direction to form a complete printed image. The first partial print is printed first, starting at or extending to a connection area. Then, the second partial print is printed with a feed towards the connection area, such that the first and second partial prints overlap in a meshing manner at the connection area. This allows partial prints to be joined together with inconspicuous transitions, even with dimensional tolerances and complex container cross-sections.