Reconfigurable Single Media Printer for Transparent Substrates
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Solution Overview
Problem
Direct-to-shape printing on transparent and semi-transparent media, such as glass bottles, faces challenges due to UV light scattering, which causes inkjet printhead fouling and inconsistent image quality, leading to delays and product loss.
Innovation Solution
A reconfigurable single media printer with a tiltable and raisable print carriage and adaptable spindle, along with precise control of media positioning and UV light application, minimizes UV exposure to printheads and ensures consistent ink curing, allowing for high-capacity processing of axially symmetric objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If UV light is used to cure ink on transparent media, then ink curing is achieved, but UV light scattering causes printhead fouling
Solution Approach 1:
A media support carriage is introduced as an intermediary component between the printhead and the media. The carriage includes a media support surface that positions the media at a controlled distance from the printhead, and a UV light shield that acts as a mediator to block scattered UV light from reaching the printhead while allowing cured ink to remain on the media surface.
Solution Approach 2:
The solution moves the problem from a two-dimensional plane (printhead-to-media distance) to three-dimensional space by introducing vertical positioning capabilities. The media support carriage can be raised and lowered to adjust the Z-axis distance between the printhead and media, while also providing angular adjustment to change the geometric relationship between UV light sources, media, and printhead.
2Manufacturing precision
If media positioning is adjusted to optimize printing, then image quality improves, but system complexity increases
Solution Approach 1:
The media support carriage serves multiple functions simultaneously: it positions the media at the correct distance from the printhead, provides angular adjustment for optimal printing geometry, supports various media types (transparent, semi-transparent, opaque), and includes UV light shielding. This multi-functionality reduces the need for separate components for each function.
Solution Approach 2:
The carriage system incorporates dynamic adjustment capabilities where the media support surface can be raised and lowered during operation, and angular positions can be changed between print jobs. This dynamic adaptability allows the system to optimize for different media types and printing requirements without requiring complete reconfiguration.
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 maintains high print job throughput while preventing printhead fouling, reducing delays and ensuring consistent image quality on transparent and semi-transparent media, enabling efficient production with a single operator.
Implementation Method 1
UV light is applied to cure ink deposited on a surface of the media
Data Source
AI summary
A system is disclosed to provide a DTS machine that is simple to operate and can through human operator control provide economic and competitive throughput speeds as compared to more complex DTS machines utilizing multiple printing tunnels and material handlers. The present invention utilizes a repositionable print carriage and a re-configurable inkjet printhead bank. The printing carriage is vertically positionable and tiltable, and includes a resizable spindle so that varying geometries of print media may be accommodated. The printer prints a single piece of media at each printing event, but maintains a printing throughput similar to DTS machines having the capability to print media in parallel printing events. Media is moved from a media loading area on the machine by a single operator into a printing tunnel and then the operator adjusts the angle of the media relative to a reconfigurable array of ink-heads to meet inkjet expression distance requirements.