The present invention generally relates to printers and specifically to vertical inkjet printing.
Printing on horizontal surfaces is well known in the art.
Printing on vertical surfaces though is a developing industry.
While printing on vertical surfaces, there is a need to create flawless image covering, as much as possible, on the printed surface.
According to an aspect of the present invention there is provided an integrated vertical inkjet printer for printing on a vertical substrate, comprising: a controller; a main trolley carrying a main trolley body; and a printing assembly, comprising: a plurality of inkjet printing head assemblies mounted on a platform; a vertical telescopic tandem beam system comprising: a first printing beam, wherein the platform is slidable along the first printing beam; and a second printing beam detachably insertable between the first printing beam and the main trolley body, a first motor configured to drive the platform vertically; and a second motor configured to drive the first printing beam along the second printing beam.
The integrated vertical inkjet printer may further comprise at least one distance sensor configured to provide accurate positioning of the integrated vertical inkjet printer in relation to the substrate.
The main trolley may be mounted on four wheels and may comprise automatic floor-leveling elements.
The integrated vertical inkjet may further comprise two vertical linear encoders configured to provide accurate location of the first and second printing beams, respectively, to the controller.
The plurality of inkjet printing head assemblies may comprise printing heads mounted above and below the platform, wherein the controller may be configured to perform special printing sequences when the heads reach the ceiling or the floor of the substrate, respectively.
According to another aspect of the present invention there is provided an integrated vertical inkjet printer for printing on a vertical substrate, comprising: a controller; a main trolley carrying a main trolley body; a first extension trolley carrying a first extension trolley body; two first horizontal rails detachably connecting the main trolley body and the first extension trolley body; and a printing assembly movable along the two horizontal rails, comprising a plurality of inkjet printing head assemblies mounted on a platform, wherein the plurality of inkjet printing head assemblies comprise printing heads mounted to the right and to the left of the platform; and wherein the controller is configured to perform special printing sequences when the heads reach the right wall or the left wall of the substrate, respectively.
The integrated vertical inkjet may further comprise: a second extension trolley carrying a second extension trolley body; two second horizontal rails detachably connecting the first extension trolley body and the second extension trolley body; a printing assembly movable along the two first horizontal rails and the two second horizontal rails, the printing assembly comprising a plurality of inkjet printing head assemblies mounted on a platform, the platform slidable along a vertical beam; a timing belt mechanism configured to provide smooth transition of the printing assembly on each of the two first and second horizontal rails and in between the two first horizontal rails and the two second horizontal rails; a first linear encoder scale connected with the two first horizontal rails; a second linear encoder scale connected with the two second horizontal rails; and a linear encoder reader comprising two reading heads, wherein only one of the reading heads is operable at any given time.
The integrated vertical inkjet printer may further comprise at least one distance sensor configured to provide accurate positioning of the integrated vertical inkjet printer in relation to the substrate.
The main trolley and the first and second extension trolleys are each may be mounted on four wheels and may comprise automatic floor-leveling elements.
The timing belt may comprise two tangential timing belts.
The integrated vertical inkjet printer may further comprise means for mapping the substrate's planar profile before or during printing.
The means for mapping may comprise a distance sensor.
The controller may further be configured to calculate a smooth distance movement profile for the printing assembly, based on the mapping.
The printing heads assembly may comprise a printing head configured to print a background color.
The background color may comprise a primer.
The integrated vertical inkjet printer may further comprise UV monochromatic light Emitting Diodes (UV LED) configured to cure the primer.
The UV LED may be mounted near the printing head assembly.
According to another aspect of the present invention there is provided a method of printing on a vertical substrate, comprising: providing a printing assembly comprising four printing head assemblies, two background printing head assemblies, two image UV monochromatic light Emitting Diodes (UV LEDs) and two background monochromatic light Emitting Diodes (UV LEDs); printing, by the two background printing head assemblies, a background color while moving in a first horizontal direction from a starting point; curing, by the two background UV LEDs, the background color; moving the two background printing head assemblies to the other side of the printing assembly; returning, by the printing assembly, in a second horizontal direction to the starting point; printing, by the printing head assemblies, while moving in the first horizontal direction an image; and curing, by the two image UV LEDs, the printed image.
The method may further comprise: moving the two background printing head assemblies to the other side of the printing assembly; continue printing the image while curing the background color; folding the background UV LEDs and continue printing the image; and moving in the second horizontal direction while curing the printed image.
According to another aspect of the present invention there is provided a timing belt mechanism, comprising: at least two pulleys; wherein at least one of the at least two pulleys is activated by a motor; and a timing belt stretched around the at least two pulleys; wherein at least part of the timing belt is configured to be in contact with a second belt thereby accurately moving the second belt.
The second belt may be a conveyor timing belt.
The timing belt mechanism may further comprise at least one encoder comprising at least one reading head and at least one encoder scale.
For better understanding of the invention and to show how the same may be carried into effect, reference will now be made, purely by way of example, to the accompanying drawings.
With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice. In the accompanying drawings:
For better understanding of the invention and to show how the same may be carried into effect, reference will now be made, purely by way of example, to the accompanying drawings.
With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice. In the accompanying drawings:
The present invention provides an integrated vertical inkjet printer to be used for printing on walls, glass or any other substrate at the customer's location.
The integrated printer of the present invention is distinguished from prior art printers, inter alia, by its mobility in a ready-to-print state, where no assembly is required on site.
Additionally, the printer is designed such that it may easily access common spaces (e.g. stairs, doorways, elevators, pavements), is adaptable to varying width (e.g., wall width) and heights (e.g., ceiling height), overcomes substrate irregularities without loss of image quality and is adaptable to various substrates by printing an appropriate primer layer simultaneously with printing the main image.
The integrated printer of the present invention is designed for minimum installation time, using its capabilities of mobility, automatic leveling and automatic initial positioning, as will be described in details below.
It will be appreciated that the starting position of the printing assembly is not limited to be the leftmost position. According to embodiments of the present invention, the printing assembly's starting position may be the rightmost position or any position between the rightmost and leftmost positions.
It will be appreciated that the initial position of the first printing beam (with printing heads platform) is not limited to be the lowest position. According to embodiments of the present invention, the first printing beam (with printing heads platform) may be at the highest position allowed by the printed substrate or at any position between the lowest and highest positions.
In each of the above positioning scenarios, together or separately, the process described in conjunction with
It will be appreciated that the process described in conjunction with
According to embodiments of the present invention, the printing process may be done by:
The moving method may be automatically selected by the system controller according to the printed substrate, image size, image location, constraints, etc.
As mentioned above, according to embodiments of the present invention the basic integrated vertical inkjet printer 100, with or without the vertical telescopic tandem beam system (e.g. with a single vertical beam on which the printing heads platform is sliding vertically) may be horizontally extended to enable printing on varying width substrates extending beyond the size of rails 200 and 210 of
The width extension may be done by two additional upper and lower horizontal rails 600 and 610 as shown in
It will be appreciated that additional trailers, trolley bodies and fixed or variable length extension rails may be similarly connected horizontally, to print an image on the entire substrate width.
It will be appreciated that the last extension may be of a varying length to fit to the substrate width or it may be a flexible folding extension.
According to embodiments of the present invention, a smooth and accurate traversing of the printing assembly between two width extensions may be enabled by:
According to embodiments of the present invention, an additional timing belt mechanism provides accurate advancement of the printing assembly along the lower horizontal rail 210 and also from the upper horizontal rail 200 to the adjacent connecting rail 194 and similarly to horizontal rail 610.
The linear encoder reader 700 provides smooth and accurate transition between two horizontal width extensions, in the direction of arrow 750. The horizontal linear encoder reader 700 has two reading heads (710, 720) positioned at a predetermined horizontal distance from each other for accurate reading of the printing assembly's location. The controller determines when to switch to the second reading head of the encoder reader when the printing assembly passes to the horizontal extension.
It will be appreciated that the timing belt mechanism 570 is not limited to the present invention. The timing belt mechanism 570 may be applicable in any transmission system, conveyor system, or any other system intended to move an object, a conveyor, etc. accurately. The timing belt mechanism 570 may serve as the primary or secondary driving medium of those systems and a plurality of units may be used.
It will be appreciated that both pulleys 810 and 820 may be passive and the conveyor belt may be moved by the timing belt mechanisms 570 of the present invention.
It will be appreciated that there is no limitation to the number of timing belt mechanisms which may be used.
According to embodiments of the present invention, each one of the timing belt mechanisms described in conjunction with
According to embodiments of the present invention, the substrate's planar profile may be mapped in a pre-scan stage of the entire substrate, by a distance sensor attached to the printing assembly, to provide accurate distance between the substrate and the printing assembly during the printing stage.
Alternatively, the pre-scan and printing may be done concurrently, where a next swath width is scanned while a current swath is being printed, by a distance sensor attached to the printing assembly.
The corrections for substrate irregularity may be made by the controller software, where a Z direction (distance from substrate) movement of the printing head assemblies is calculated to provide a smooth Z movement profile.
As opposed to traditional inkjet printers, in which the substrate is fed to the printer and the printing heads have the ability to traverse the entire width of the substrate, the printer of the present invention is stationed near a stationary substrate where printing may be required end-to-end and where the printing head assemblies' start and end positions may be limited (e.g. by perpendicular walls).
This constraint defines 3 distinct horizontal printing areas, as schematically shown in
Area I, where the printing head assemblies are limited by the left wall;
Area II with no horizontal limitation to the printing head assemblies;
Area III, where the printing head assemblies are limited by the right wall.
Printing in areas I and III require special sequencing of the data sent from the controller to each column of printing head assemblies, as described below in reference to Area I and in conjunction with
Since there is a distance 810 between the printing head assemblies' columns (820, 840) and since the printing resolution is higher than the printing head assemblies' native resolution and since part of the printing nozzles may be inoperable at any given time, there is need for more than one printing pass to complete the printing of each area on the substrate, i.e., interlacing. This is normally done by one or more subsequent printing head assemblies/columns “filling” the gaps.
The problem arises when there are no subsequent printing head assemblies, due to a physical barrier (e.g., wall) such as for column 820 in area I. To solve this problem, the printing assembly is constructed so that one column of printing head assemblies (820 in
The same technique is applied to the rightmost column of printing head assemblies 840 in area III.
The same constraints define 3 distinct vertical printing areas, constrained by the ceiling and the floor, as schematically shown in
Area IV, where the printing head assemblies are limited by the ceiling;
Area V with no vertical limitation to the printing head assemblies;
Area VI, where the printing head assemblies are limited by the floor.
Printing in areas IV and VI require special sequencing of the data sent from the controller to each column of printing head assemblies, as described below in reference to Area IV and in conjunction with
To solve this problem, the printing assembly is constructed so that one row of printing head assemblies (850 in
The same technique is applied to the bottom row of printing head assemblies 860 in area VI.
As mentioned before, according to embodiments of the present invention, the printer of the present invention may be stationed near a stationary substrate where printing may be required end-to-end and where the printing head assemblies' start and end positions may be limited (e.g. by perpendicular walls).
Nevertheless, the objective of the present invention is to enable printing essentially up to the edges of the substrate (e.g., left wall, right wall, ceiling, floor), around objects (e.g. electrical outlet, switch, etc.), near obstacles, etc.
According to embodiments of the present invention, the system controller may manipulate the printed image's data while printing when the printing head(s) is tilted in order to compensate for the printing angle created by the tilt.
According to embodiments of the present invention, the printing may combine simultaneous printing of white color (or any other suitable color) as background and the 4 basic colors (Cyan, Magenta, Yellow, Black), or any kind or number of printing colors of the required design. There is no limitation to the number of printing head assemblies and/or the number of colors.
According to embodiments of the present invention, a primer may be printed to retain the ink to the substrate during the printing process and up to the curing. The primer may be printed as a separate color or mixed with the background color.
According to embodiments of the present invention, the primer is selected to be compatible with the substrate.
Fixation and curing are achieved using monochromatic UV Light Emitting Diodes (LED). According to embodiments of the present invention the UV LEDs are mounted near the printing head assemblies.
The ink formulation is selected to be compatible with the UV LED's wavelengths; it can be a single UV wavelength or combination of wavelengths.
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It will be appreciated that during the image printing process the printing heads tilting mechanism may enable printing essentially up to the ceiling, floor, left wall, right wall, objects, obstacles, etc.
It will be appreciated that a similar process (or parts of the process) may be performed when:
It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the present invention is defined by the appended claims and includes combinations and sub-combinations of the various features described hereinabove as well as variations and modifications thereof which would occur to persons skilled in the art upon reading the foregoing description.
This patent application claims priority from and is related to U.S. Provisional Patent Application Ser. No. 62/467,142, filed Mar. 5, 2017, this U.S. Provisional patent application incorporated by reference in its entirety herein.
Filing Document | Filing Date | Country | Kind |
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PCT/IB2018/051371 | 3/4/2018 | WO |
Publishing Document | Publishing Date | Country | Kind |
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WO2018/163036 | 9/13/2018 | WO | A |
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Machine translation of CN 203046466 U. (Year: 2013). |
Machine translation of CN 104842651 U. (Year: 2015). |
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Number | Date | Country | |
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20200062003 A1 | Feb 2020 | US |
Number | Date | Country | |
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62467142 | Mar 2017 | US |