Segmented Fountain Roller for Multi-Ink Flexographic Printing
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Solution Overview
Problem
There is a need for a simple inking system for flexographic printing that can simultaneously provide different inks to different portions of a printing plate, especially one that operates with low volumes of ink.
Innovation Solution
The inking system includes an anilox roller with cells for ink transfer, a fountain roller with ink transfer zones and recessed zones, and a segmented ink tray with segments corresponding to each ink transfer zone of the fountain roller, allowing for precise distribution of different inks to various zones of the printing plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional ink tray is used to supply ink to the fountain roller, then the ink distribution is simple and the device structure is simple, but different inks cannot be supplied to different zones of the printing plate
Solution Approach 1:
The ink tray is divided into multiple segmented zones (first ink tray zone, second ink tray zone, etc.), each corresponding to a specific zone of the fountain roller. This segmentation allows different inks to be supplied to different fountain roller zones, which then transfer different inks to different zones of the printing plate, enabling multi-ink printing capability while maintaining a relatively simple overall structure
Solution Approach 2:
Different zones of the fountain roller are assigned different functions by supplying different inks to different fountain roller zones. For example, one zone receives transparent ink for printing transparent patterns while another zone receives opaque ink for printing alignment marks. This local differentiation of ink properties enables the printing plate to have different functional zones with appropriate ink characteristics
2Loss of substance
If a conventional ink tray supplies ink to the entire fountain roller, then the device structure is simple, but ink usage is excessive especially for high-cost inks
Solution Approach 1:
The ink tray is segmented into multiple independent zones, each supplying ink to a specific portion of the fountain roller. This segmentation restricts ink to only the areas where it is needed, preventing unnecessary ink usage across the entire fountain roller surface and reducing waste of expensive inks
Solution Approach 2:
Each ink tray zone is designed to supply ink locally to its corresponding fountain roller zone, ensuring that ink is applied only where required for specific printing functions. This localized ink supply optimizes ink usage by eliminating unnecessary ink application in areas where different ink or no ink is needed
3Illumination intensity
If transparent ink is used for printing conductor patterns, then the optical transparency is improved, but alignment accuracy deteriorates due to invisibility of the patterns
Solution Approach 1:
Different zones of the printing plate are assigned different ink types based on their functional requirements. Transparent ink is applied to zones requiring optical transparency (conductor patterns), while opaque ink is applied to zones requiring visibility for alignment (alignment marks). This local differentiation of ink properties simultaneously achieves both optical transparency and alignment accuracy
Solution Approach 2:
The printing plate and ink supply system are segmented into functional zones: one zone uses transparent ink for conductor pattern printing where optical transparency is critical, while another zone uses opaque ink for alignment mark printing where visibility is critical. This functional segmentation resolves the contradiction between transparency and alignment accuracy
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 system enables the use of different inks in different zones of the printing plate, allowing for accurate alignment of patterns and reducing ink usage to smaller volumes, which is particularly advantageous for high-cost inks.
Implementation Method 1
anilox roller with a cylindrical outer surface having a plurality of cells, the cells being indentations in the outer surface of the anilox roller configured to transfer ink to the flexographic printing plate
Data Source
AI summary
An inking system is used to transfer a plurality of different inks to an anilox roller in a flexographic printing plate in a flexographic printing system. A fountain roller includes a plurality of ink transfer zones separated by recessed zones, and a segmented ink tray includes a plurality of ink tray segments corresponding to each of the ink transfer zones, wherein the fountain roller is positioned such that the ink transfer zones contact the anilox roller. Each ink transfer zone of the fountain roller is adapted to receive ink from the corresponding ink tray segment and transfer the received ink to a corresponding zone of the anilox roller.