Single-pass Ink-jet Printer for Wood Panels

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current processes for printing wood-based flat panels are time-consuming, costly, and lack productivity, especially when dealing with large quantities and non-smooth surfaces, as they require complex preprinting operations and are not adaptable to specific client requirements.

Innovation Solution

A single pass ink-jet printer with multiple print heads for each color is used, allowing for printing without surface contact, combined with a protective coating application to enhance durability, and controlled by an electronic processor for efficient and flexible production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional printing machines (rotogravure or flexographic) are used for printing wood-based panels, then printing quality can be achieved, but production time increases significantly (6-8 hours downtime) and costs increase due to complex preprinting operations

Engineering Contradiction:

Improveprinting qualityVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces conventional mechanical printing systems (rotogravure or flexographic machines requiring cylinder installation and adjustment) with a digital ink-jet printing system. The ink-jet printer directly deposits ink onto the panel surface without requiring physical printing cylinders, eliminating the 6-8 hour downtime associated with cylinder installation and adjustment while maintaining printing quality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses digital copying technology where the design is stored as digital data and reproduced on the panel surface through ink-jet printing. This eliminates the need for physical printing cylinders and their associated installation and adjustment processes, significantly reducing production time while maintaining printing precision.

Inventive Principle:

Principle #26Copying

2Adaptability or versatility

If ink-jet plotter is used for printing wood-based panels, then surface flexibility is improved, but productivity decreases and unit cost increases significantly

Engineering Contradiction:

Improvesurface flexibilityVSAvoidproduction speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent divides the printing system into multiple independent ink-jet print heads arranged in parallel, each capable of depositing different colors simultaneously. This segmentation allows multiple colors to be printed in parallel across the panel width, dramatically increasing productivity compared to a single-pass plotter while maintaining the ability to handle non-smooth surfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements a continuous printing process where the panel moves through the printing system and multiple print heads continuously deposit ink across the entire surface. This continuous action eliminates the stop-start nature of traditional plotter printing, significantly improving productivity while maintaining surface adaptability.

Inventive Principle:

Principle #20Continuity of useful action

3Productivity

If multiple print heads for each color are used to cover entire panel width, then printing speed increases, but device complexity increases

Engineering Contradiction:

Improveprinting speedVSAvoidnumber of print heads

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent employs a single ink-jet printing system that can print multiple colors by depositing different colored inks sequentially or simultaneously using multiple print heads. This universal system replaces the need for separate printing machines for each color, reducing overall device complexity while maintaining high productivity through parallel multi-color printing.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 significantly reduces production time and cost, enables high productivity, and allows for personalized printing with maximum flexibility, enabling the production of any quantity, including small batches, with reduced stock requirements and improved surface resistance.

Implementation Method 1

an ink-jet printer, controlled by an electronic processor, for printing the surface of said flat element

Methodology Applied

Scientific EffectInk-jet printing:

Implementation Method 2

applying conventional coating or covering products to the printed surface of the flat element, to form a substantially transparent protective layer

Methodology Applied

Scientific EffectCoating: Coatings

Data Source

PatentEP2080630B2Production line for manufacturing of flat wood-based panels with a printed upper surface

Publication Date: 2019.05.15 FRATI

Figure 1~1a
Figure 2
Figure 3

AI summary

A process for printing wood-based flat elements (10), comprising a preliminary step of graphic composition by means of an electronic processor and relative software, and a printing step. To print the wood-based flat elements (10) an ink-jet printer (12) of the single-pass type is used controlled by the electronic processor. Either the flat element (10) is maintained at rest and the printer (12) moves relative thereto during the printing operation, in order to print the entire surface thereof involved, or the flat element (10) and the printer move simultaneously, with the printer moving parallel to the surface of the flat element.