Patent Grant
11724519
The present disclosure generally relates to digital printing systems and methods, including digital printing systems and methods involving linear and/or indexed conveyance, as well as controlled and/or modular components.
There is a desire for solutions and/or options that, among other things, can further improve or optimize the digital printing of containers, including the digital printing of plastic containers and glass containers at relatively high speeds, with improved flexibility, and/or with higher throughput. The foregoing discussion is intended only to illustrate examples of the present field and should not be taken as a disavowal of scope.
A digital printing system includes a track for conveying a plurality of containers to or through a plurality of process locations, and a plurality of print heads configured for digital printing on the plurality of containers. In embodiments, which may have linear paths or portions thereof, the system may be configured to index sets of the plurality of containers (e.g., groups of two or three containers) to or through the plurality of process locations—which may involve print heads or other forms of treatment or processing.
The foregoing and other aspects, features, details, utilities, and/or advantages of embodiments of the present disclosure will be apparent from reading the following description, and from reviewing the accompanying drawings.
Reference will now be made in detail to embodiments of the present disclosure, examples of which are described herein and illustrated in the accompanying drawings. While the present disclosure will be described in conjunction with embodiments and/or examples, it will be understood that they are not intended to limit the present disclosure to these embodiments and/or examples. On the contrary, the present disclosure is intended to cover alternatives, modifications, and equivalents.
In embodiments, the containers 20 may be gripped (e.g., individually gripped) at or about their upper portions or necks by a mechanical device (such as a plurality of grippers that may be attached to a shuttle) and the containers may be conveyed about a track by such device(s). However, other forms of container conveyance, including a plurality of base cups or base holders, could also be utilized. With embodiments, the device(s) used to grip/convey containers may be configured to rotate the containers up to or more than 180 degrees—such as to present different portions of a container to various process steps/locations.
Without limitation, in an embodiment, the containers 20 may enter and be directed to a device 50 (which may include a wheel) that may convey or direct the containers onto a track 60 for subsequent processing. Device 50 may be configured to index or move/shift containers in desired groupings (as opposed to continuously moving containers through/along a system). For example, in the illustrated system of
In embodiments, the track 60 may, for example and without limitation, have a generally extended oval or oblong shape. Embodiments of a track may have a first generally straight portion/segment 62, a first curved portion/segment 64, a second generally straight portion/segment 66, and a second curved portion/segment 68. As generally illustrated in
In embodiments, such as generally illustrated in
The system 10 may, for example and without limitation, include the ability to print a plurality of different inks (or ink colors), including those commonly involved with color or process printing. Such colors commonly include cyan, magenta, yellow, and black.
In embodiments, the system may be configured to print (e.g., subsequently or substantially simultaneously) on opposing sides of a container. For example and without limitation, as generally illustrated in
Depending upon whether a base coat is intended or desired, the system 10 may eliminate or skip certain processes such as those shown in
With embodiments, to optimize print head utilization, and to better maximize printer output, it can be desirable to reduce the amount of time that is consumed moving product in and out of print or printer position. With rotary print systems, a center wheel may be used to mount associated container carriers. The container carriers are typically spaced equally around the circumference of the wheel. With rotary systems, a large wheel diameter can be required in view of the associated size of the print hardware. However, a large wheel, with a large diameter, will typically have a comparatively large mass. That in turn can require greater inertial force, and necessitate substantial energy for controlling movement and indexing. Such systems can also require an undesirable amount of time associated with the indexing of the wheel, as well as issues associated with the torque demands of the system.
As appreciated in connection with the present disclosure, increasing print head utilization and/or increasing production output/throughput may involve, inter alia, a reduction in index speed associated with the containers. That may, for example, involve the reduction of mass associated with the associated movement and/or indexing of the containers to be printed. Among other things, an embodiment of the present disclosure comprises a plurality of container carriers, which may be independently controlled. Such independent container carriers may carry or transport a small number of containers, for example and without limitation, one, two, or three containers. Further, such container carriers may be comprised of comparatively light weight material (e.g., aluminum). Further, in contrast to hardware associated with rotary print systems (where the entire mass of the wheel must move together), utilizing container carriers, such as described herein, can reduce indexing time and optimize/maximize printhead utilization. Typical peak power of a rotary print system may be about 4600 W. Comparatively typical peak power of a container system according to teachings of the instant disclosure may be about 800 W (e.g., a reduction of more than 80%).
Such container carriers may be attachable (or coupled) and detachable (or de-coupled) to and from a track which may proceed past one or more print stations, which may involve one or more print heads. In embodiments, each container carrier may be attached or coupled to the track. For example and without limitation, each container carrier may be magnetically coupled to a servo track, which can allow for the individual control of the velocity and position along the track for each independent container carrier. An associated position controller may, for example, accelerate at very high rates (for example, about 18 m/s2, as opposed to typical rotary print system maximum acceleration of about 3 m/s2) and/or maintain very tightly toleranced positional accuracy. For example, in embodiments, the accuracy or repeatability may be about 100μ, may be about 50μ, and for some applications may be about 10μ or even less than 10μ.
By way of comparative example and without limitation, embodiments of the present disclosure can exhibit a significant increase in productivity when compared to a typical indexing wheel rotary print system.
Typical indexing wheel calculations may be generally as follows:
In contrast, calculations for an embodiment of a digital printing system according to aspects or teachings of the present disclosure may be generally as follows:
As demonstrated by the above calculations, a significant comparative reduction in index time with embodiments of the present disclosure can result in a print utilization percent that is significantly higher (e.g., as much or greater than 70%) when compared with a typical rotary index wheel system.
As generally illustrated in
An embodiment of a container carrier assembly 140, including a container carrier (or shuttle) 120 is generally illustrated in several views in
Embodiments of a container carrier assembly 140 may include other components in addition to a container carrier 120. For example and as generally illustrated, a container carrier assembly 140 may include one or more base supports 150, one or more actuators 160 (e.g., push up actuators), one or more grippers 170 (e.g., neck grippers), and one or more encoders 180.
In embodiments, the base support 150 may be insertable and/or exchangeable and may be configured to accommodate a lower portion of various different containers. For example only, and as generally illustrated in
With embodiments, one or more actuators 160 may be connected to a base support 150 and may be configured to rotate and/or vertically move (raise or lower) a base support (and hence a container if included or supported therein or thereby).
In embodiments, one or more grippers 170 may be configured to hold and/or retain a portion of a container (for example, and without limitation, a plastic bottle). For example, a gripper 170 may be configured to hold and/or retain a portion of a container, such as a neck portion of a container (e.g., at or about a support flange or tamper evident formation). Embodiments of a gripper 170 may be comprised, for example, of stainless steel, and/or may be configured to control a radial position/orientation of an associated container.
In embodiments, an encoder 180 may be operatively connected to a gripper 170. An encoder may, for example and without limitation, may control a radial position of a gripper (and hence a container held by a gripper), may receive power, and may transmit information (including for example via radio frequency (RF) or light data). In embodiments the container carrier assembly and/or an encoder may utilize, for example, inductive power or lithium ion power. Moreover, the power associated with each container carrier assembly may be charged or replenished at one or more print stations 130.
Further, as generally shown in
In contrast with typical rotary printing systems, which generally run at a constant velocity throughout, embodiments of the disclosed digital printing system can run at different speeds or velocities. Moreover, embodiments of the disclosed digital printing system can be modular and flexible. That is, for example, the system can add or take away container carriers, and container carriers can be included in the system in various combinations (as to desired printing and/or types of containers), and can be run in various combinations, as well as in sequence or in parallel.
With embodiments, when the system is moving the container carriers may not be powered. One or more various motors may be fixed at different processing locations/stations about a track. When a container carrier (with containers for printing) arrive at a print station and/or where a motor is located, there may be a power exchange engagement with the container carrier and/or other relevant components.
Various embodiments are described herein for various apparatuses, systems, and/or methods. Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments as described in the specification and illustrated in the accompanying drawings. It will be understood by those skilled in the art, however, that the embodiments may be practiced without such specific details. In other instances, well-known operations, components, and elements have not been described in detail so as not to obscure the embodiments described in the specification. Those of ordinary skill in the art will understand that the embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and do not necessarily limit the scope of the embodiments.
Reference throughout the specification to “various embodiments,” “with embodiments,” “in embodiments,” or “an embodiment,” or the like, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “with embodiments,” “in embodiments,” or “an embodiment,” or the like, in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment/example may be combined, in whole or in part, with the features, structures, functions, and/or characteristics of one or more other embodiments/examples without limitation given that such combination is not illogical or non-functional. Moreover, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the scope thereof.
It should be understood that references to a single element are not necessarily so limited and may include one or more of such element. Any directional references (e.g., plus, minus, upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of embodiments.
Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily imply that two elements are directly connected/coupled and in fixed relation to each other. The use of “e.g.” in the specification is to be construed broadly and is used to provide non-limiting examples of embodiments of the disclosure, and the disclosure is not limited to such examples. Uses of “and” and “or” are to be construed broadly (e.g., to be treated as “and/or”). For example and without limitation, uses of “and” do not necessarily require all elements or features listed, and uses of “or” are intended to be inclusive unless such a construction would be illogical.
While examples of dimensions of certain components may be described herein, such dimensions are provided as non-limiting examples and the components may have other dimensions.
While processes, systems, and methods may be described herein in connection with one or more steps in a particular sequence, it should be understood that such methods may be practiced with the steps in a different order, with certain steps performed simultaneously, with additional steps, and/or with certain described steps omitted.
It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the present disclosure.
This application claims the benefit of priority to U.S. Provisional Application No. 62/771,303, filed Nov. 26, 2018, the entire disclosure of which is incorporated herein by reference.
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| 20030210299 | Min | Nov 2003 | A1 |
| 20040099160 | Tweedy | May 2004 | A1 |
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| Number | Date | Country | |
|---|---|---|---|
| 20200164669 A1 | May 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62771303 | Nov 2018 | US |
