Variable Data Lithographic Inkjet Imaging System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional ink-based digital printing systems face challenges such as stringent material requirements, vapor re-deposition, complex laser imaging, high costs, and inefficiencies in ink transfer and waste management, limiting high-speed, high-quality printing with lithographic inks.
Innovation Solution
An ink-based digital printing system utilizing an inkjet imaging system that jets a low-viscosity resin as a base marking material onto the imaging member, which dries to create a stable surface with significant energy contrast, allowing for efficient ink transfer and reduced waste, and uses a dampening fluid to enhance image resolution and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional lithographic printing techniques are used, then high quality printing and cost-effective inks are achieved, but true high-speed variable data printing cannot be accommodated
Solution Approach 1:
The patent replaces conventional mechanical lithographic printing with a digital inkjet-based system. The inkjet subsystem digitally deposits lithographic ink directly onto the imaging member based on variable image data, eliminating the need for physical plate changes and enabling high-speed variable data printing while maintaining lithographic quality
Solution Approach 2:
The patent changes the fundamental operating parameters of lithographic printing by using a digital inkjet delivery system instead of traditional mechanical means. This allows the system to accommodate variable data at high speeds while preserving the essential lithographic printing characteristics through controlled ink deposition and curing parameters
2Adaptability or versatility
If digital ink-based printing systems are used, then variable data printing is enabled, but stringent material requirements and tight system latitude are imposed
Solution Approach 1:
The patent employs a disposable or easily replaceable imaging member with a reimageable surface layer that can be rapidly renewed. This approach simplifies material requirements by eliminating the need for complex, long-lasting conventional printing plates, allowing the system to handle variable data printing with reduced system latitude constraints
Solution Approach 2:
The system applies dampening fluid to the imaging member surface before ink deposition, pre-conditioning the surface to ensure optimal ink reception and transfer. This preliminary action simplifies subsequent printing operations and reduces the tightness of system latitude requirements by establishing consistent baseline conditions
3Manufacturing precision
If laser patterning of dampening fluid is used, then variable data imaging is achieved, but vapor re-deposition and complex imaging processes occur
Solution Approach 1:
The patent extracts and removes vapor generated during the printing process through dedicated vapor removal mechanisms. This prevents vapor re-deposition on the imaging member and substrate, maintaining image resolution while enabling continuous high-speed variable data printing without the harmful effects of vapor accumulation
Solution Approach 2:
The patent introduces an intermediary curing step that rapidly solidifies the deposited lithographic ink before transfer. This intermediary action prevents vapor re-deposition by establishing a stable, non-volatile ink layer that can be cleanly transferred to the substrate, maintaining precision while eliminating harmful vapor effects
4Reliability
If conventional ink transfer processes are used, then lithographic printing is achieved, but ink waste and cleaning requirements increase
Solution Approach 1:
The patent implements a system where the imaging member is rapidly cleaned and reused for subsequent variable data printing operations. The ink transfer process is optimized to minimize waste, and any residual ink is efficiently removed through cleaning subsystems, allowing continuous operation with reduced material loss and maintained printing quality
Solution Approach 2:
The patent enables continuous printing operation by rapidly cycling the imaging member through print, transfer, and clean phases. This continuous operation minimizes ink waste by maintaining consistent transfer efficiency across multiple variable data impressions without requiring frequent plate changes or extensive cleaning interruptions
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 achieves improved printing performance with increased surface property contrast, enhanced system latitude, and reduced waste, enabling high-speed, high-quality ink-based digital printing with efficient ink usage and lower operational costs.
Implementation Method 1
jetting a low-viscosity resin onto an imaging member surface according to digital image data to form a patterned fluid layer that is dried to form a base marking material image
Implementation Method 2
applying a dampening fluid to the imaging member after the jetting of the base marking material onto the imaging member surface during a printing process
Data Source
AI summary
A system for ink-base digital printing includes an imaging member; an inkjet system for applying a base marking material to the imaging member to for a pattern according to digital image data; a dampening fluid metering system configured for applying dampening fluid to the imaging member after the applying base marking material; and an inking system configured for applying ink to the imaging member, the ink adhering to the base marking material pattern. Methods include jetting base marking material onto the imaging member according to image data, applying dampening fluid, inking the imaging member, and optionally pre-curing the resulting ink image, which enables 99% or greater transfer of the applied ink from the imaging member to a substrate.