Auxiliary Printing Module for Opaque Base Image Switching
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Solution Overview
Problem
Existing digital printing machines do not effectively allow the printing of an opaque base image using either ink-jet or analogue printing units based on specific printing requirements, which is crucial for achieving high opacity and improving print quality on transparent, translucent, or colored web substrates.
Innovation Solution
A digital printing machine and method that incorporates an auxiliary printing module with both ink-jet and analogue printing units, allowing the selection of either unit to print an opaque base image based on cost and efficiency, using a control unit to calculate and implement the required ink thickness and opacity values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the opaque base image is printed using an ink-jet printing unit, then the printing cost increases and printing speed decreases, but the printing flexibility and opacity control improve
Solution Approach 1:
The system dynamically selects between ink-jet and analogue printing units based on real-time job requirements, substrate properties, and opacity targets. The control unit adjusts the printing configuration from static to dynamic, allowing the machine to switch between high-speed analogue printing for non-critical areas and high-precision ink-jet printing for opacity-critical base images.
Solution Approach 2:
The control unit modifies printing parameters such as ink thickness, number of passes, and printing density based on the selected printing unit and substrate characteristics. For ink-jet printing of opaque base images, the system adjusts ink deposition parameters to achieve optimal opacity while minimizing impact on printing speed.
2Manufacturing precision
If the opaque base image is printed using an ink-jet printing unit, then the printing precision and opacity control improve, but the printing cost increases
Solution Approach 1:
The system applies different printing qualities to different parts of the printing job. Opaque base images requiring high precision are printed using ink-jet units with controlled ink thickness and multiple passes, while other monochrome images are printed using cost-effective analogue units. This localized application of high-precision printing minimizes overall cost while ensuring opacity requirements are met where critical.
Solution Approach 2:
The control unit applies partial ink coverage or selective printing only where opacity is required, rather than printing entire areas with maximum ink. For transparent or translucent substrates, the system calculates the minimum necessary ink deposition to achieve target opacity, reducing material cost while maintaining precision.
3Productivity
If the opaque base image is printed using an analogue printing unit, then the printing cost decreases and printing speed increases, but the opacity control and printing flexibility decrease
Solution Approach 1:
The printing machine is designed with multi-functionality, incorporating both ink-jet and analogue printing units that can handle the same printing tasks. The control unit universally manages both printing technologies, selecting the appropriate unit based on job requirements, substrate type, opacity targets, and cost considerations, thereby providing adaptability without sacrificing productivity.
Solution Approach 2:
The system dynamically configures the printing process by selecting between analogue and ink-jet units based on real-time analysis of job characteristics. For high-volume jobs with standard opacity requirements, analogue units provide high speed; for jobs requiring precise opacity control or printing on challenging substrates, the system dynamically switches to ink-jet units.
4Reliability
If the opaque base image is printed with increased ink thickness to improve opacity, then the opacity value improves, but the drying time increases and printing speed decreases
Solution Approach 1:
Instead of applying thick ink in a single pass, the system uses periodic action by printing multiple thinner passes. The ink-jet unit deposits ink in sequential layers, allowing partial drying or curing between passes. This approach achieves the required opacity while significantly reducing total drying time compared to a single thick application.
Solution Approach 2:
The control unit dynamically adjusts ink thickness based on substrate properties and opacity requirements. For highly absorbent or transparent substrates, the system increases ink deposition; for less demanding substrates, it reduces ink thickness to minimize drying time. The system also dynamically selects between ink-jet and analogue units based on the trade-off between opacity achievement and drying time.
Data Source
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AI summary
Digital printing machine and operation method thereof, the digital printing machine comprising a main printing module (70) and an auxiliary printing module (50) associated in succession with the same web conveyance path, the auxiliar printing module comprising an auxiliar ink-jet printing unit (10), an analogue printing unit (20), and at least one auxiliar drying/curing unit (30) controlled by a control unit storing an opaque base image (43), and an operation method of the auxiliary printing unit comprising supplying the auxiliar ink-jet printing unit (10) with first ink (11) and the second analogue printing unit (20) with second ink (21) of the same color; the control unit implementing a printing configuration of the auxiliary printing module (50) between a first printing configuration, where the opaque base image (43) is printed solely with the auxiliar ink-jet printing unit (10), and a second printing configuration where the opaque base image (43) is printed solely with the analogue printing unit (20).