Overlapping Printheads for Multi-Color Absorbent Article Printing
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Solution Overview
Problem
Existing methods for digitally printing absorbent article components require multiple printheads to achieve multi-colored graphics, leading to increased costs and complexity, with offline printing causing quality issues and additional handling costs due to the need for separate printing and registration processes.
Innovation Solution
A method involving two printheads arranged in an overlapping configuration in the cross direction to cover the substrate width, allowing for multiple colors to be printed using fewer printheads, reducing waste and costs while maintaining high print resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple printheads are used to achieve multi-colored graphics, then color variety and design complexity are improved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple printheads into a single integrated printing system where multiple ink delivery systems share common components including a single print head assembly, support structure, and control system. This merging approach enables multi-colored graphics while reducing the number of separate printhead units required, thereby lowering device complexity and cost.
Solution Approach 2:
The printing system is designed with universal components that can handle multiple ink types and colors through a single printhead assembly. The system uses a multi-channel ink delivery mechanism where each channel can deliver different colored inks to the same print head, allowing one printhead to perform the function of multiple separate printheads.
2Ease of manufacture
If offline printing is performed separately from converting lines, then printing operations are independent, but handling costs and substrate quality deteriorate due to additional handling and storage
Solution Approach 1:
The patent integrates the printing operation directly into the converting line, combining previously separate processes into a unified continuous operation. The printing system is positioned to print on substrates during their movement through the converting line, eliminating the need for separate offline printing, storage, and re-loading operations.
Solution Approach 2:
The printing process operates continuously as substrates move through the converting line without interruption. The ink delivery system maintains continuous ink flow to the printhead, and the printing action occurs continuously along the substrate path, eliminating stop-start operations and intermediate storage steps.
3Productivity
If contact printing processes are used for high production rates, then productivity is improved, but design flexibility is reduced requiring shutdown for graphic changes
Solution Approach 1:
The system employs a programmable printhead controller that can dynamically change printing patterns and designs without physical reconfiguration. The ink delivery system can be controlled to switch between different graphic patterns on demand, allowing high-speed continuous operation while maintaining full design flexibility through software control rather than mechanical changes.
4Area of stationary object
If printheads extend beyond the printing area to cover full substrate width, then printing coverage is improved, but unused printhead portions create waste and increase cost
Solution Approach 1:
The patent implements a printhead assembly where different sections are assigned to different functions: some nozzles are positioned to print only when needed for specific graphic elements, while other sections remain inactive. The ink delivery system provides ink selectively to active nozzle sections, preventing waste from unused printhead portions while maintaining full printing coverage when required.
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 enables efficient, cost-effective production of multi-colored graphics on absorbent articles by minimizing the number of printheads required, improving print resolution, and reducing handling and registration complexities.
Implementation Method 1
The inkjet printhead is positioned to print the advancing substrate with printed regions having a desired machine direction print resolution
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
The methods and apparatuses relate to digitally printing a substrate using first and second printheads (302 and 304). The first printhead includes a first printhead width (PI) and the second printhead includes a second printhead width (P2). The first printhead overlaps with the second printhead such that the first printhead width overlaps with the second printhead width in a cross direction (CD). The overlapping first and second printheads form a first print zone (252), an overlapping print zone (250), and a second print zone (254). The first printhead may deposit droplets onto the substrate in the first print zone and/or the overlapping zone. The second printhead may deposit droplets onto the substrate in the overlapping print zone and/ or the second print zone. The droplets deposited in the overlapping print zone may unite to illustrate multiple colors and/or may remain ununited. By using overlapping printheads, various colors may be illustrated and the width of the substrate may be printed on.