System and process for in-line digital printing
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Solution Overview
Problem
Existing digital printing processes for absorptive substrates require separate pretreatment and printing steps, leading to long production times and inefficiencies, particularly in wet-on-wet in-line processes that demand precise parameter selection.
Innovation Solution
A closed-loop in-line printing system with multiple processing stations, including pretreatment, drying, and printing, where objects are independently controlled and processed on conveyor tracks, allowing simultaneous and efficient application of pretreatment and ink formulations with synchronized movement and optional drying/curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate pretreatment and printing steps are used, then proper drying of the surface is ensured, but production time is significantly extended
Solution Approach 1:
The patent combines pretreatment and printing operations into a single integrated system where the pretreatment unit applies coating to the substrate, followed immediately by the printing unit applying ink in the same production line, eliminating the need for separate drying periods between operations
Solution Approach 2:
The system maintains continuous operation by having the substrate move continuously through pretreatment, drying, and printing stations without interruption, allowing the substrate to be processed through all stages in an unbroken sequence rather than stopping between operations
2Productivity
If wet-on-wet in-line printing is used, then drying time is eliminated and production speed increases, but parameter selection becomes more difficult and quality control is compromised
Solution Approach 1:
The system controls the transition from wet pretreatment layer to wet ink layer by precisely managing drying parameters (temperature, humidity, exposure time) to achieve optimal moisture content that ensures proper ink adhesion and print quality
Solution Approach 2:
The system incorporates control mechanisms that monitor and adjust processing parameters in real-time based on substrate conditions, ensuring consistent quality across different materials and environmental conditions
3Reliability
If multiple separate processing stations are used, then each operation can be optimized independently, but system complexity and space requirements increase
Solution Approach 1:
The system employs a conveyor-based platform that serves multiple functions: transporting substrates through pretreatment, providing controlled drying environment, positioning substrates for printing, and coordinating timing between different processing stations
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
The system significantly reduces printing time, improves resolution, and lowers manufacturing costs while enabling continuous production of printed objects with enhanced quality on various substrates.
Implementation Method 1
a drying tool for drying the aqueous pretreatment layer
Implementation Method 2
an ink drying tool configured to at least partially dry the ink on the dry pretreatment layer
Data Source
AI summary
The technology generally concerns an in-line system and process for forming an image on an object.