Inkjet Web Edge Bending for Flat Decorative Surface Printing
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Solution Overview
Problem
Inkjet printing on continuous substrate webs, particularly those with edge-waviness, results in inferior print quality due to irregular transport speed, web swim, stretch or shrink, and non-flatness at the edges, leading to wrinkles and crashes against the inkjet printhead.
Innovation Solution
The method involves bending the substrate web along parallel lines to form elongated strips that are supported below the printing zone, using edge bender units to stabilize the web, and applying vacuum or air to hold the strips in place, ensuring a stable and flat printing surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the substrate web is transported with edge-waviness, then the transport process is simple, but print quality deteriorates due to wrinkles and instability
Solution Approach 1:
The edge bender units are positioned upstream of the printing zone to pre-bend the edges of the substrate web before it enters the printing area. This preliminary action stabilizes the web configuration in advance, preventing wrinkles and ensuring consistent print quality without complicating the overall transport process
Solution Approach 2:
Instead of attempting to flatten the entire substrate web, the invention applies localized bending only to the edges of the web. This local modification stabilizes the web where it matters most for printing while maintaining the simplicity of the overall transport system
2Manufacturing precision
If calendering is applied to flatten the substrate web before printing, then edge waviness is reduced, but the method is not feasible for any type of material
Solution Approach 1:
The invention changes the approach from applying pressure (calendering) to applying controlled bending forces. By using adjustable edge bender units that can accommodate different material properties, the system achieves edge stabilization across diverse substrate materials without requiring material-specific calibration
3Reliability
If the substrate web is held down against the support zone, then printing stability improves, but edge-waviness causes crashes against the printhead
Solution Approach 1:
The edge bender units perform a preliminary anti-action by pre-bending the edges to counteract the tendency of the web to wave or lift during transport. This prevents the web from crashing against the printhead while allowing the holding down force to maintain printing stability
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 prevents wrinkles and enhances print quality by maintaining a stable substrate web during transport, allowing for consistent ink application and reducing the risk of printhead damage.
Implementation Method 1
applying vacuum or air to hold the strips in place
Data Source
AI summary
An inkjet printing method on a continuous substrate web (100), having a pair of edges (1011, 1021), comprising the steps: a) forming a pair of elongated strips (101, 102) by bending said substrate web (100) along a pair of lines (1010, 1020) wherein each line is parallel to the pair of edges (1011, 1021); and b) supporting said bent substrate web in a support zone (201) of a printer 200) wherein said pair of elongated strips (101, 102) are oriented below said zone (201); and printing an image (500) on said supported substrate web by an inkjet-printhead (202) of said printer (200).