Modular Printing Unit for Magnetic Coating and Selective Curing
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Solution Overview
Problem
Existing printing technologies lack an efficient and cost-effective method to integrate high-resolution image information into coating materials with magnetic or magnetizable particles, particularly in sheet-fed printing presses, while maintaining control over curing properties and layer thickness.
Innovation Solution
A printing unit with two base modules, each having form-bound and non-impact printing points, alignment cylinders, and curing devices, allows for the application of coating materials with alignable particles, followed by selective curing using printheads and radiation sources, enabling high-resolution image incorporation and layer control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If coating materials with magnetic or magnetizable particles are applied and aligned using traditional screen printing and alignment devices, then optical effects dependent on viewing angle can be created, but the manufacturing process becomes complex and costly without efficient integration of high-resolution image information
Solution Approach 1:
The patent combines form-bound printing (screen printing) and non-impact printing (inkjet printing) into a single integrated printing unit. The screen printing unit applies coating material with magnetic particles, while the inkjet printing unit selectively deposits image information. Both printing units share common components including alignment cylinders with magnetic fields and curing devices, merging previously separate processes into one unified system that achieves high-resolution imaging while reducing overall process complexity
Solution Approach 2:
The printing unit is designed with modular base modules that can accommodate different printing functions. Each base module contains installation areas for rotary transport bodies, alignment cylinders, and curing devices that can be configured for multiple operations. This universal design allows the same physical structure to perform coating application, magnetic alignment, inkjet printing, and curing operations, reducing device complexity while maintaining high-resolution capabilities
2Manufacturing precision
If multiple printing units are integrated into sheet-fed printing presses, then high-resolution image information can be incorporated into coating materials, but manufacturing effort and costs increase
Solution Approach 1:
The printing unit is divided into modular base modules that can be independently manufactured and then assembled. Each base module contains a complete set of functions including form-bound printing, non-impact printing, alignment, and curing. This segmentation allows for simplified manufacturing of individual modules using standard processes, reducing overall manufacturing effort while enabling high-resolution image integration through the coordinated operation of multiple modules
Solution Approach 2:
The patent employs a nested modular architecture where smaller functional components are integrated within larger base modules. Rotary transport bodies are positioned in installation areas within base modules, which themselves contain alignment cylinders and curing devices. This nested structure allows compact integration of multiple functions within standardized modules, reducing manufacturing complexity and cost while achieving high-resolution printing capabilities
3Adaptability or versatility
If selective curing is performed using UV LEDs or radiation sources, then curing properties can be controlled, but the device complexity increases
Solution Approach 1:
The patent uses magnetic fields generated by alignment cylinders as an intermediary mechanism to control the curing process. The alignment cylinders, which already exist as part of the alignment system, generate magnetic fields that can be selectively activated to trigger curing at specific locations and times. This intermediary use of existing magnetic field components allows for precise curing control without adding separate complex curing devices, reducing overall system complexity while maintaining versatile curing control
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 high-resolution image information integration into coating materials with precise curing and layer thickness control, reducing manufacturing effort and costs through modular design and resource efficiency.
Implementation Method 1
align the particles using an alignment device, for example, one that uses magnetic fields
Implementation Method 2
the layer of the coating material is then crosslinked by means of radiation
Data Source
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AI summary
The invention relates to a printing unit (700), which comprises a plate cylinder (752), an impression cylinder (708) and a frame having two frame side walls (702; 703), which are mutually opposite in a transverse direction (A), wherein the printing unit (700) has two base modules (704), which each have two base side walls (706; 707), each base side wall being part of a corresponding frame side wall (702; 703), and wherein each base module (704) has four installation regions (726; 727; 728; 729) for rotational transport bodies (708; 709; 711; 712; 713; 714), the relative positions of which in both base modules (704) match, and wherein the first two installation regions (726; 727) along a transport path form a selection group of the base module (704) in question, and wherein exactly one of the installation regions (726; 727) of the selection group of the first base module (704) contains an impression cylinder (708) which, together with a plate cylinder (752), forms a printing position (758), and wherein each installation region (726; 727; 728; 729) contains a rotational transport body (708; 709; 711; 712; 713; 714), and wherein a printhead (791) of a non-impact printing position (787) is directed at a rotational transport body (709; 711; 712; 713) disposed in an installation region (726; 727; 728; 729) of the first base module (704), and wherein a printhead (791) of a non-impact printing position (787) is directed at a rotational transport body (709; 711; 712; 713) disposed in an installation region (726; 727; 728; 729) of the second base module (704).