Solid Ink Printing on Fibrous Containers via Forced Air Heating

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Solution Overview

Problem

Existing direct-to-object printers using UV curable inks are not suitable for printing on fibrous food and beverage containers as the inks do not cure properly and are not approved for food contact, while solid inks require pressure that can compromise the structural integrity of these containers.

Innovation Solution

A printing system that uses solid ink and a forced air heater to preheat the surface of fibrous objects, allowing the ink to melt and affix to the surface without applying pressure, ensuring the ink's safety for food contact and maintaining the container's integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If UV curable inks are used in direct-to-object printers, then printing speed and customization capability are improved, but the inks do not cure properly on fibrous objects and are not approved for food contact

Engineering Contradiction:

Improveprinting speedVSAvoidink curing completeness

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent changes the physical state parameter of the ink from liquid UV-curable ink to solid ink, and changes the curing mechanism parameter from UV radiation to thermal melting. This allows the ink to be applied to fibrous objects without penetration issues while maintaining food contact safety approval.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the UV radiation curing mechanism with a thermal melting mechanism. Instead of using UV light to cure the ink, the system uses heated air to melt solid ink particles, allowing them to affix to the object surface without requiring UV penetration through the fibrous material.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If solid inks are used in direct-to-object printers, then food contact safety is improved, but pressure must be applied to affix the ink which compromises container structural integrity

Engineering Contradiction:

Improvefood contact safetyVSAvoidcontainer structural integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent replaces the mechanical pressure application system with a thermal field system. Instead of using physical pressure to affix the solid ink to the container surface, the system uses heated air to melt the ink particles, allowing them to bond to the surface through thermal energy rather than mechanical force.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes the phase transition of solid ink from solid to liquid state through heating. The heated air melts the solid ink particles, transforming them into a liquid state that can flow and affix to the container surface, then solidifies upon cooling to create a permanent mark without requiring external pressure.

Inventive Principle:

Principle #36Phase transitions

3Reliability

If solid ink is ejected without heating, then the ink remains in solid form and cannot affix to the surface, but heating requires a heating mechanism that increases device complexity

Engineering Contradiction:

Improveink affixing effectivenessVSAvoidheating mechanism complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent uses a forced air heating system where heated air is directed onto the container surface to melt the solid ink. This pneumatic approach uses airflow rather than direct contact heating elements, reducing device complexity while effectively transferring thermal energy to melt and affix the ink particles to the surface.

Inventive Principle:

Principle #29Pneumatics and hydraulics

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

Enables custom printing on food and beverage containers with solid ink images that are safe for food contact, enhancing legibility and professional appearance without compromising the structural integrity of the containers.

Implementation Method 1

a forced air heater configured to direct heated air toward the surface of the object

Methodology Applied

Scientific EffectForced convection heating: Forced Convection

Implementation Method 2

Solid inks are inks that are loaded into printers in solid form and then heating to a melting point so the liquid ink can be supplied

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS11110722B2System for directly printing fibrous objects with solid ink images

Publication Date: 2021.09.07 GENESEE VALLEY INNOVATIONS LLC

AI summary

A printer includes a spindle that rotates a fibrous object opposite a plurality of printheads while a forced air heater directs heated air toward the surface of the fibrous object. The plurality of printheads eject drops of solid ink onto the surface of the fibrous object to form a solid ink image on the fibrous object and the heated air affixes the solid ink image to the surface of the fibrous object without requiring pressure to affix the solid ink image to the fibrous object.