Synchronized Pad Printing for High-Speed Slip-Free Image Transfer
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Solution Overview
Problem
Existing pad printing technologies face limitations in achieving high print quality, particularly photorealistic quality, while maintaining high capacity and speed, especially when dealing with complex geometries and non-developable surfaces.
Innovation Solution
A combined pad printing system that integrates continuous motion of the printing plate with synchronized pad-based image transfer, allowing for high-speed, slip-free deposition of ink or other mediums onto products, including complex geometries, by using a system that synchronizes the motion of the pad, product, and printing plate to ensure precise positioning and quality transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rotary printing is used to increase printing speed, then productivity is improved, but print quality deteriorates due to slip between pad roller and printing plate
Solution Approach 1:
The invention uses dynamic synchronization where the pad roller and product move at different speeds during different phases of the printing cycle. During the printing phase, both are stationary relative to each other (no slip), while during transfer phases they move at different speeds, optimizing both quality and productivity
Solution Approach 2:
The system employs periodic indexing motion where the pad roller and product are alternately stationary and moving. The printing plate rotates continuously while the pad roller and product remain stationary during printing, then index to new positions during transfer, creating periodic cycles that maintain quality while enabling high speed
2Manufacturing precision
If traditional linear pad printing is used to maintain print quality, then manufacturing precision is improved, but productivity deteriorates due to decoupled inking and take-up motions
Solution Approach 1:
The printing plate rotates continuously throughout the entire cycle without stopping, eliminating idle time. The decoupled motions of inking and take-up are replaced by continuous rotation of the plate with synchronized indexing of the pad roller and product, maintaining continuous useful action while improving speed
Solution Approach 2:
The system dynamically synchronizes the motion of the pad roller and product with the rotating printing plate. During printing, all components are stationary relative to each other for quality; during transfer, they index to new positions, enabling the plate to present fresh images continuously for high productivity
3Productivity
If rotary printing with synchronized motion is used to increase speed, then productivity is improved, but manufacturing precision deteriorates due to inability to print on complex geometries
Solution Approach 1:
The printing cycle is segmented into distinct phases (inking, transfer, printing, cleaning) with the pad roller and product indexing to different positions for each phase. This segmentation allows the system to maintain stationary printing for quality on complex geometries while achieving high overall speed through parallel operations
Solution Approach 2:
The pad roller acts as an intermediary that can conform to complex product geometries while being driven by the rotating printing plate. The pad roller transfers the image from the plate to the product, accommodating various shapes and surfaces while maintaining the synchronized motion needed for high speed
Data Source
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AI summary
This invention relates to a printing device of products (5) through an intermediate carrier (20), in particular of the pad (4) type, which is remarkable in that it consists of a combined intermediate support, respectively pad printing system for printing objects of the type including control surfaces, consisting of a pad based transfer system for transferring media via pad, with the endless belt, and a method therefor.