1. Field
The present invention relates generally to printing, and particularly, to printing on cylindrical objects, and more particularly to printing on hollow cylindrical objects, such as cans, and hollow, partially cylindrical objects, such as bottles.
2. Description of the Problem and Related Art
Current methods of printing indicia on cylindrical objects, such as cans or bottles, include either spray painting, gravure application, or the like, as is known in the art. While these methods have great utility in mass production of such objects, they do not lend themselves to other markets, such as novelty advertising on bottles, which benefit from the ability to change designs rapidly.
Ink jet printing is well-known, and because it can be digitally controlled using a computer, it has the flexibility to allow a user to change designs as desired. Only recently, however, have advances in technology been made to enable true image rendering on non-planar objects. For example, U.S. Pat. No. 7,111,915 entitled, Methods and Apparatus for Image Transfer, issued Sep. 26, 2006, to Martinez, and LaCaze (one of the inventors herein) and which is incorporated herein fully by reference, describes an ink jet printer for the printing of indicia on solid non-planar objects such as baseball bats. Multiple bats are held in a horizontal carousel structure and are positioned relative to printheads and then rotated in relation to the printhead which is computer-controlled to apply ink according to a programmed image file.
However, this structure is not suitable for hollow cans or two-piece bottles. What is needed is a programmable ink jet printer that allows for the proofing of two-piece can and bottle designs, without the complexity and cost associated with in-line can and bottle production and printing, as well as allowing for low-speed, high-quality, flexible commercial production with instantaneously variable images on the object.
Another example, specifically for cylindrical objects, such as cans or bottles, is found in the co-owned, and co-pending, U.S. Pub. App. 2010/0295885, entitled Apparatuses for Printing on Generally Cylindrical Objects and Related Methods, published Nov. 25, 2010 by LaCaze (one of the inventors herein) and which is incorporated herein fully by reference, describes an ink jet printer for the printing of generally cylindrical objects such as cans and bottles. Generally cylindrical objects, such as cans and bottles, are positioned relative to printheads by a combination of axial and rotary motion, as well as indexing without the printheads jetting ink. The object is conveyed to a “tunnel” formed by the printheads that is transverse to the axis along which the object travels, where the printheads are disposed at the same axial position. Alternatively, multiple printheads may be disposed singularly in series, along the axis of travel. The printheads are computer-controlled to apply ink according to a programmed image file.
For purposes of summarizing the invention, certain aspects, advantages, and novel features of the invention have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any one particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that combines certain features of various embodiments and still be within the scope contemplated by the appended claims.
Disclosed hereinbelow is an apparatus for non-contact printing of images on generally cylindrical objects, particularly hollow cylindrical objects or hollow partially-cylindrical objects, for example, cans and bottles and including two-piece cans and bottles. It will also be apparent to one skilled in the relevant arts with the benefit of reading this disclosure that solid cylindrical objects and solid partially-cylindrical objects may also be printed by the described apparatuses.
In the one embodiment, each hollow cylindrical object is either hand-loaded or mechanically loaded via automation, utilizing structures and controls already known in the art, and secured by vacuum on a mandrel to prevent slippage, which is part of a carriage assembly that functions to convey the object along an axis of travel, (or axially, as used herein) beneath a series of digitally-controlled printheads and rotate the object in front of such printheads while ink is deposited to the object, in order to produce the desired printed design. The ink is also either partially or fully cured immediately after printing by an energy-emitting means positioned directly beneath the object, which is able to function while beneath the printheads or anytime during the functioning of the invention.
An exemplary carriage assembly may be mounted to a slide actuator, which is in turn fixedly mounted to a mounting frame, whereby the carriage assembly is free to traverse along the slide actuator. Also attached to said frame is any number of print tunnels containing—in the described first embodiment—four printheads capable of depositing four individual colors, or coatings, lacquers or overvarnish as known in the present art.
In the preferred operation of the first embodiment, the carriage advances the object through the first print tunnel, thereby under the printheads, while the object is rotated in synchronization with the deposition of ink from the computer-controlled printheads, said ink delivered from supply means located above the print tunnel. Such sequencing of the deposition of ink, rotation of the object and axial advancement thereof is variable, being dictated by several input factors, including desired print design and resolution, object diameter and length, printhead length and deposition rate, desired ink density, as well as axial displacement, or staggering of the printheads to achieve the desired results. The exact amount of axial printhead staggering is dictated by the aforementioned input factors, with the intention of keeping the object in continuous axial/rotary motion within the print tunnel(s) while simultaneously printing on the object, maximizing effective printing speed/efficiency and minimizing the time the printheads are not jetting ink. Simultaneously the energy-emitting means either partially or completely cures the ink. The carriage continues to axially advance the object in synchronization with its rotation and the jetting of ink from the printheads such that the entire length of the object may be printed by the first print tunnel.
The axial advancement/rotating/energy emitting action may for as many print tunnels as are being utilized to complete the intended printed design on the object. In one embodiment, the carriage axially returns to the loading position, ejects the object, and is then ready for loading the next object. However, the invention should not be understood as limited to this ejection, return and loading sequence as these functions may be performed in any order. Additionally, the drawings illustrate two print tunnels with four printheads each, but the number of print tunnels and/or the number of printheads per print tunnel should not be considered a limiting factor.
Examples of loading and unloading hollow cylindrical objects—such as cans and cups that are used to make cans—via automation utilizing structures and controls already known in the art are disclosed in U.S. Pat. No. 4,921,093 entitled Infeed Means for High Speed Continuous Motion Decorator, issued May 1, 1990 to Peters, Hamot and Ver Hoven; U.S. Pat. No. 4,928,511 entitled Rotary Cup Infeed, issued May 29, 1990 to Sirvet; U.S. Pat. No. 5,231,926 entitled Apparatus and Method for Substantially Reducing Can Spacing and Speed to Match Chain Pins, issued Aug. 3, 1993 to Williams, Sirvet, Gabel and Burke; U.S. Pat. No. 5,566,567 entitled Rotary Cup Infeed, issued Oct. 22, 1996 to Main; U.S. Pat. No. 5,749,631 entitled Dual Can Rotating Transfer Plate to Conveyor Belt, issued May 12, 1998 to Williams; and U.S. Pat. No. 6,467,609 entitled Can Transfer Rotating Plate System, issued Oct. 22, 2002 to Williams and Di Donato.
In an alternative operation of the first embodiment, the object continues to be printed as the carriage assembly returns to the loading position versus traversing through the print tunnel(s) without the printheads jetting ink, as in the preferred operation. The carriage axially advances back to the loading position while simultaneously rotating and printing the object via a second pass to complete any desired printing not achieved during the first pass beneath the printheads within the print tunnel(s). This serves to further maximize effective printing speed/efficiency by further minimizing the time the printheads are not jetting ink. As with the first pass, during the second (return) pass the energy-emitting means simultaneously either partially or completely cures the ink. The object may pass through the print tunnel(s) for as many repetitions as necessary in either direction to complete the desired printed design at the desired print resolution and ink density. After the desired design is completely printed, the object returns to the loading position—either having been printed during such return axial motion or not, where it is blown off and the next object is loaded and ready to be printed.
In a second embodiment of the invention, each hollow partially-cylindrical object (or bottle) is either hand-loaded or mechanically loaded via automation, utilizing structures and controls already known in the art, and secured at the closed end by vacuum on an object holding assembly and at the open end by an object clamping assembly, which are both part of a carriage assembly that functions to axially position the bottle beneath a series of digitally-controlled printheads and rotate the bottle in front of such printheads while ink is deposited to the bottle, in order to produce the desired printed design. The ink is also either partially or fully cured immediately after printing by an energy-emitting means positioned directly beneath the bottle, which is able to function while beneath the printheads or anytime during the functioning of the invention.
The carriage assembly is fixedly mounted to a slide actuator, which is in turn fixedly mounted to a mounting frame, whereby the carriage assembly is free to traverse along the slide actuator. Also attached to said frame is any number of print tunnels containing—as in the described first embodiment—four printheads capable of depositing four individual colors, or coatings, lacquers or overvarnish as known in the present art.
In the preferred operation of this second embodiment—as with the preferred operation of the first embodiment—the carriage axially advances the object through the first print tunnel, thereby under the printheads, while the object is rotated in synchronization with the deposition of ink from the computer-controlled printheads, said ink delivered from supply means located above the print tunnel. Such sequencing of the deposition of ink, rotation of the object and axial advancement thereof is variable, being dictated by several input factors, including desired print design and resolution, object diameter and length, printhead length and deposition rate, desired ink density, as well as axial displacement, or staggering of the printheads to achieve the desired results. The exact amount of staggering is dictated by the aforementioned input factors, with the intention of keeping the object in continuous axial/rotary motion within the print tunnel(s) while simultaneously printing the object, with the intention of maximizing effective printing speed/efficiency by minimizing the time the printheads are not jetting ink. Simultaneously the energy-emitting means either partially or completely cures the ink. The carriage continues to axially advance the object in synchronization with its rotation and the jetting of ink from the printheads such that the entire length of the object may be printed by the first print tunnel.
As with the first embodiment, in this second embodiment the axial advancement/rotating/energy emitting functions continue for as many print tunnels as are being utilized to complete the intended printed design on the object. Again, the carriage axially returns to the loading position, ejects the object, and is then ready for loading the next object. However, the invention should not be understood as limited to this ejection, return and loading sequence as these functions may be performed in any order. Additionally, the drawings illustrate two print tunnels with four printheads each, but the number of print tunnels and/or the number of printheads per print tunnel should not be considered a limiting factor.
Examples of loading and unloading hollow partially cylindrical objects—such as bottles—via automation utilizing structures and controls already known in the art are disclosed in U.S. Pat. No. 4,199,049 entitled Bottle Unscrambler and Loader, issued Apr. 22, 1980 to Vamvakas; U.S. Pat. No. 4,530,433 entitled Bottle-Holder Pincers Forming a Link in a Conveyor Chain, issued Jul. 23, 1985 to Cucchetto; U.S. Pat. No. 6,109,429 entitled Oriented Bottle Conveyor, issued Aug. 29, 2000 to Messer; U.S. Pat. No. 6,748,983 entitled Conveyor for Bottle-Filling Machine, issued Jun. 15, 2004 to Bausch; and U.S. Pat. No. 7,229,110 entitled Bottle Loading and Unloading Tool with Extendable Arms, issued Jun. 12, 2007 to Tye.
In an alternative operation of the second embodiment, the object continues to be printed as the carriage assembly returns to the loading station versus traversing through the print tunnel(s) without the printheads jetting ink, as in the preferred operation. The carriage axially advances back to the loading position while simultaneously rotating the bottle to complete any printing not achieved during the first pass beneath the printheads within the print tunnel(s). This serves to further maximize effective printing speed/efficiency by further minimizing the time the printheads are not jetting ink. As with the first pass, during the second (return) pass the energy-emitting means simultaneously either partially or completely cures the ink. The bottle may pass through the print tunnel(s) for as many repetitions as necessary in either direction to complete the desired printed design at the desired print resolution and ink density. After the desired design is completely printed, the bottle returns to the loading position, the object clamping assembly releases the open end of the bottle and air is applied to the object holding assembly to release the bottle, which may be unloaded by hand or mechanically unloaded via automation utilizing structures and controls already known in the art; the next bottle is then ready for loading.
In a third embodiment, each hollow cylindrical object, may be either hand-loaded or mechanically loaded via automation utilizing structures and controls already known in the art, and secured by vacuum on a mandrel to prevent slippage, which is part of a carriage assembly that functions to axially position the object relative to a series of digitally-controlled printheads and rotate the object in front of such printheads while ink is deposited to the object surface, in order to produce the desired printed design. The ink is also either partially or fully cured immediately after printing by an energy-emitting means positioned directly beneath the object, which is able to function while beneath the printheads or anytime during the functioning of the invention.
The carriage assembly is fixedly mounted to a slide actuator, which is in turn fixedly mounted to a mounting frame, whereby the carriage assembly is free to traverse along the slide actuator. Also attached to the frame is any number of print tunnels containing four printheads capable of depositing four individual colors, or coatings, lacquers or overvarnish as known in the present art.
In the preferred operation of the third embodiment, the carriage axially advances the object through the first print tunnel, thereby under the printheads, while the object is rotated in synchronization with the deposition of ink from the computer-controlled printheads, said ink delivered from supply means located above the print tunnel. Such sequencing of the deposition of ink, rotation of the object and axial advancement thereof is variable, being dictated by several input factors, including desired print design and resolution, object diameter and length, printhead length and deposition rate, desired ink density, as well as axial displacement, or staggering of the printheads to achieve the desired results. The exact amount of staggering is dictated by the aforementioned input factors, with the intention of keeping the object in continuous axial/rotary motion within the print tunnel(s) while simultaneously printing the object, with the intention of maximizing effective printing speed/efficiency by minimizing the time the printheads are not jetting ink. Simultaneously the energy-emitting means either partially or completely cures the ink. The carriage continues to axially advance the object in synchronization with its rotation and jetting of ink such that the entire length of the object may be printed by the first print tunnel. The axial advancement/rotating/energy emitting functions continue for as many print tunnels as are being utilized to complete the intended printed design on the object. The carriage continues to axially advance the object in the same direction as when printing, until it reaches the opposite end of the printer, where there is located another loading position, ejects the printed object, and is then ready for loading the next object at this second loading position located at the opposite end of the first loading position. This serves to further maximize effective printing speed/efficiency by further minimizing the time the printheads are not jetting ink.
In an alternative operation of the third embodiment, the object continues to be printed as the carriage assembly returns toward the original loading position, while simultaneously rotating and printing the object via a second pass to continue any desired printing not completed during the first pass beneath the printheads within the print tunnel(s). As with the first pass, during the second pass the energy-emitting means simultaneously either partially or completely cures the ink. The object then reverses direction again for an additional, or third pass through the print tunnel(s) until it reaches the end opposite the original loading position, where is located the aforementioned second loading position, blows the printed object off via compressed air, and is then ready for loading the next object at this second loading position located at the opposite end of the first loading position. This alternative operation of the third embodiment is meant to accommodate designs requiring 3 or more odd-numbered passes as determined by the design input factors, while maximizing effective printing speed/efficiency by further minimizing the time the printheads are not jetting ink.
In a fourth embodiment, each hollow partially-cylindrical object (or bottle) is either hand-loaded or mechanically loaded via automation utilizing structures and controls already known in the art and secured at the closed end by vacuum on an object holding assembly and at the open end by an object clamping assembly, which are both part of a carriage assembly that functions to axially position the bottle relative to a series of digitally-controlled printheads and rotate the bottle in front of such printheads while ink is deposited to the bottle, in order to produce the desired printed design. The ink is also either partially or fully cured immediately after printing by an energy-emitting means positioned directly beneath the bottle, which is able to function while beneath the printheads or anytime during the functioning of the invention.
The carriage assembly is fixedly mounted to a slide actuator, which is in turn fixedly mounted to a mounting frame, whereby the carriage assembly is free to traverse along the slide actuator. Also attached to the frame is any number of print tunnels containing four printheads capable of depositing four individual colors, or coatings, lacquers or overvarnish as known in the present art.
In the preferred operation of the fourth embodiment, the carriage axially advances the object through the first print tunnel, thereby under the printheads, while the bottle is rotated in synchronization with the deposition of ink from the computer-controlled printheads, said ink delivered from supply means located above the print tunnel. Such sequencing of the deposition of ink, rotation of the bottle and axial advancement thereof is variable, being dictated by several input factors, including desired print design and resolution, bottle diameter and length, printhead length and deposition rate, desired ink density, as well as axial displacement, or staggering of the printheads to achieve the desired results. The exact amount of staggering is dictated by the aforementioned input factors, with the intention of keeping the bottle in continuous axial/rotary motion within the print tunnel(s) while simultaneously printing the bottle, thereby maximizing effective printing speed/efficiency by minimizing the time the printheads are not jetting ink. Simultaneously the energy-emitting means either partially or completely cures the ink. The carriage continues to axially advance the bottle in synchronization with its rotation such that the entire length of the bottle may be printed by the first print tunnel.
The axial advancement/rotating/energy emitting functions continue for as many print tunnels as are being utilized to complete the intended printed design on the bottle. The carriage continues to axially advance the bottle in the same direction as when printing, until it reaches the opposite end of the printer, where there is located another loading position, the object clamping assembly releases the open end of the bottle and air is applied to the object holding assembly to release the bottle; the next bottle is then ready for loading. The present invention drawings illustrate two print tunnels with four printheads each, but the number of print tunnels and/or the number of printheads per print tunnel should not be considered a limiting factor.
Examples of loading and unloading hollow partially cylindrical objects—such as bottles—via automation utilizing structures and controls already known in the art are already described within the second embodiment (U.S. Pat. Nos. 4,199,049; 4,530,433; 6,109,429; 6,748,983; 7,229,110).
In an alternative operation of the fourth embodiment, the bottle continues to be printed as the carriage assembly returns toward the original loading position, while simultaneously rotating and printing the bottle via a second pass to continue any desired printing not completed during the first pass beneath the printheads within the print tunnel(s). This serves to further maximize effective printing speed/efficiency by further minimizing the time the printheads are not jetting ink. As with the first pass, during the return pass the energy-emitting means simultaneously either partially or completely cures the ink. The bottle then reverses direction again for an additional, or third pass through the print tunnel(s) until it reaches the end opposite the original loading position, where is located the aforementioned second loading position, the object clamping assembly releases the open end of the bottle and air is applied to the object holding assembly to release the bottle; the next bottle is then ready for loading. This alternative operation of the fourth embodiment is meant to accommodate designs requiring 3 or more odd-numbered passes as determined by the design input factors, while maximizing effective printing speed/efficiency by further minimizing the time the printheads are not jetting ink.
These and other embodiments of the present invention will also become readily apparent to those skilled in the art from the following detailed description of the embodiments having reference to the attached figures, the invention not being limited to any particular embodiment(s) disclosed.
The present invention is described with reference to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.
The various embodiments of the present invention and their advantages are best understood by referring to
This invention may be provided in other specific forms and embodiments without departing from the essential characteristics as described herein. The embodiments described above are to be considered in all aspects as illustrative only and not restrictive in any manner. The following claims rather than the foregoing description indicate the scope of the invention.
Referring first to
The carriage assembly 2, includes a mandrel assembly 9 mounted to be aligned along the direction of travel, dimensioned to internally support a hollow cylindrical object to be printed 8. The mandrel assembly 9 is coupled to a rotational drive assembly 7. In this embodiment, the carriage assembly 2 is shown to also include the energy curing assembly 6 mounted to the carriage directly underneath the mandrel assembly 9 such that curing energy (discussed below) is radiated onto the mandrel assembly 9 and specifically onto the hollow cylindrical object to be printed 8 mounted thereon.
In
In an alternative operation of this first embodiment, the carriage assembly 2 is commanded to reverse direction after the first, single-direction pass through the print tunnel(s) 3—as shown in FIG. 24—while simultaneously rotating so that during such return motion printing may continue, with the printheads 25 jetting ink in the reverse order from the first pass beneath them. The necessity to continue to print in this manner will be dictated by the desired print design and resolution, hollow cylindrical object to be printed 8 diameter and length, printhead 25 length and deposition rate, desired ink density, as well as axial displacement of the printheads 25 to achieve the desired results.
A second exemplary embodiment of a printing apparatus is shown in
A third exemplary embodiment of a printing apparatus is shown in
After loading at the secondary loading position 65, the hollow cylindrical object to be printed 8 is axially advanced back under the printheads 25, as depicted in
In another operation of the third embodiment of the invention, these forward and reverse passes through the print tunnel(s) 3 may continue for as many repetitions as required to complete the intended design, being dictated by the desired print design and resolution, hollow cylindrical object to be printed 8 diameter and length, printhead 25 length and deposition rate, desired ink density, as well as axial displacement, or staggering of the printheads 25 to achieve the desired results. In this embodiment, the total number of passes—both forward and reverse—would by convention be an odd number (3, 5, 7, etc.) as an even number of passes would insinuate only a first loading position 64, which is described within the first embodiment of the invention.
A fourth exemplary embodiment of a printing apparatus is shown in
In the preferred operation of this fourth embodiment for hollow partially-cylindrical object to be printed 38—as with the preferred operation of the third embodiment for hollow cylindrical object to be printed 8—the hollow partially-cylindrical object to be printed 38 axially advances beneath the first set of printheads 25 after being loaded at the first loading position 64. After completion of printing in the requisite number of print tunnel(s) 3, the hollow partially-cylindrical object to be printed 38 continues to axially advance until reaching the secondary loading position 65, axially opposite the first loading position 63—as depicted in
In another operation of the fourth embodiment, these forward and reverse passes through the print tunnel(s) 3 may continue for as many repetitions as required to complete the intended design, as dictated by desired print design and resolution, hollow partially-cylindrical object to be printed 38 diameter and length, printhead 25 length and deposition rate, desired ink density, as well as axial displacement, or staggering of the printheads 25 to achieve the desired results. In this embodiment, the total number of passes—both forward and reverse—would by convention be an odd number (3, 5, 7, etc.) as an even number of passes would insinuate only a first loading position 64, which is described above with in reference to the first embodiment above.
Functions of the apparatus described above are controlled through instructions executed by a computer-based control system 70 which may be housed in the support frame 4. A control system 70 suitable for use with all embodiments described above includes, for example, one or more processors. The computer system 70 can also include a main memory, preferably a random access memory (RAM), and can also include a secondary memory. The secondary memory can include, for example, a hard disk drive and/or a removable storage drive. The removable storage drive reads from and/or writes to a removable storage unit in a well-known manner. The removable storage unit, represents a floppy disk, magnetic tape, optical disk, and the like, which is read by and written to by the removable storage drive. The removable storage unit includes a computer usable storage medium having stored therein computer software and/or data.
The secondary memory can include other similar means for allowing computer programs or other instructions to be loaded into the computer system. Such means can include, for example, a removable storage unit and an interface. Examples of such can include a program cartridge and cartridge interface (such as that found in video game devices), a removable memory chip (such as an EPROM, or PROM) and associated socket, and other removable storage units and interfaces which allow software and data to be transferred from the removable storage unit to the computer system.
Computer programs (also called computer control logic) are stored in the main memory and/or secondary memory. Computer programs can also be received via a communications interface. Such computer programs, when executed, enable the computer system to perform certain features of the present invention as discussed herein. In particular, the computer programs, when executed, enable a control processor to perform and/or cause the performance of features of the present invention. Accordingly, such computer programs represent controllers of the computer system.
In an embodiment where the invention is implemented using software, the software can be stored in a computer program product and loaded into the computer system using the removable storage drive, the memory chips or the communications interface. The control logic (software), when executed by a control processor, causes the control processor to perform certain functions of the embodiments described herein.
In other embodiments, features of the apparatus are implemented primarily in hardware using, for example, hardware components such as application specific integrated circuits (ASICs) or field-programmable gated arrays (FPGAs). Implementation of the hardware state machine so as to perform the functions described herein will be apparent to persons skilled in the relevant art(s). In yet another embodiment, features of the invention can be implemented using a combination of both hardware and software.
As described above and shown in the associated drawings, the present invention comprises apparatuses for printing on generally cylindrical objects and related methods. While particular embodiments of the invention have been described, it will be understood, however, that the invention is not limited thereto, since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. It is, therefore, contemplated by the appended claims to cover any such modifications that incorporate those features or those improvements that embody the spirit and scope of the present invention.
This application claims priority to U.S. Provisional Application 61/479,106 filed, Apr. 26, 2011, which is incorporated by reference herein.
Number | Date | Country | |
---|---|---|---|
61479106 | Apr 2011 | US |