Loop Conveying Path for Flat Object Printing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing printing systems for flat objects, such as cards, face challenges in efficiently printing on one or both sides due to complex mechanics, high costs, and difficulties in adapting to varying production volumes, especially for small and medium batch sizes, leading to inefficiencies in card order and production time.

Innovation Solution

A device and method utilizing a loop-shaped conveyor path with sections for individual and stacked object handling, featuring input and discharge conveyors, collectors, and a stack conveyor to manage the printing of both sides of flat objects in batches, allowing for efficient handling and processing of small to medium production volumes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a single-pass printing system with multiple print heads is used, then printing speed and productivity are improved, but the system complexity and cost increase significantly

Engineering Contradiction:

Improveprinting speedVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The printing system is divided into multiple independent print heads, each handling a specific color or printing function. Each print head operates independently with its own ink reservoir and nozzle array, allowing modular maintenance and operation while achieving high-speed multi-color printing capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple print heads are combined in a single printing station, with each print head positioned to print on the same card simultaneously or in rapid succession. This merging of multiple printing functions into one station eliminates the need for multiple separate printing systems while maintaining high productivity

Inventive Principle:

Principle #5Merging (Combining)

2Manufacturing precision

If cards are fed individually through the printing station, then printing precision and quality are improved, but the production time and cycle time increase

Engineering Contradiction:

Improveprinting precisionVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Cards are pre-aligned and positioned on the conveying path before reaching the printing station. The conveying system ensures proper card orientation and spacing in advance, allowing the printing process to proceed without interruption or repositioning, thus maintaining precision while reducing cycle time

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The conveying path enables continuous card feed through the printing station without stopping or intermittent processing. Cards move continuously through the printing zone while being printed, eliminating idle time between printing operations and maintaining constant productivity

Inventive Principle:

Principle #20Continuity of useful action

3Adaptability or versatility

If a loop-shaped conveying path with stack handling is used, then adaptability to small and medium batch volumes is improved, but the conveying path length and device complexity increase

Engineering Contradiction:

Improvebatch volume adaptabilityVSAvoidconveying path length

Core Design Contradiction:

Adaptability or versatilityVSLength of stationary object

Solution Approach 1:

The conveying path is designed as a flexible loop system that can dynamically adjust its operation mode. The same conveying path can handle cards individually for high-precision printing or process stacks for higher-volume production, allowing the system to adapt to different batch sizes without requiring separate conveying systems for each mode

Inventive Principle:

Principle #15Dynamics

4Device complexity

If individual card transport without buffer function is used, then the system simplicity is maintained, but the ability to compensate for different process times is lost

Engineering Contradiction:

Improvesystem simplicityVSAvoidproduction efficiency

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The conveying path operates in two distinct operational dimensions: individual card conveyance for precision-critical operations and stack conveyance for volume-efficient processing. This dimensional flexibility allows the system to optimize for either simplicity or productivity depending on the specific production requirements without compromising the other

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS11840105B2Device and method for printing on one or both sides of a plurality of flat objects

Publication Date: 2023.12.12 MUEHLBAUEHR AG

AI summary

An apparatus for printing on one or both sides of flat objects. The apparatus includes a loop-shaped conveying path for the flat objects; a feed conveyor configured to feed the objects to be printed into a first section of the conveying path; a printer configured to print the objects one at a time; a first discharge conveyor configured to discharge the objects to be printed one at a time downstream of the printer from the first section towards a second section; a first collector configured to collect the objects downstream of the first discharge conveyor at the second section discharged from the first discharge conveyor in a stack; a stack conveyor configured to convey a (partial) stack of the objects along the second section; and a second collector configured to receive at least one (partial) stack and feed the objects upstream to the printer into the first section.