Patent Application
20240343053
None.
The present invention relates to a method for an inkjet printing device to print on curved, cylindrical surfaces like test tubes, bottles, and other cylindrical objects using UV curable inks and methods thereof.
Various methods and systems currently exist to mark the surface of tubes or vials (the terms are interchangeable and any reference herein to one, refers to both) or other objects or articles, with various advantages and disadvantages. Examples of some of such methods will be described herein, but it should be noted that some of these examples are not generally used in the life sciences field.
Manual marking using a marker or pen may be inexpensive, easy to use, and may be done on a variety of types of tube. However, it also may be laborious, may be prone to human error, may be inconsistent, and may not be able to accommodate barcodes effectively. Printing flat adhesive labels on standard computer printers or thermal transfer printers and hand-applying them to objects may be inexpensive, may be easy to use, and may be done on a variety of tubes. However, the process of applying the labels may be laborious and may be inconsistently placed on the object and/or prone to error. Furthermore, labels made of adhesive glue can possibly fall away from a vial when presented with extreme cold or hot environments or when aggressive solvents are applied. Heat shrink tubes may also be laborious to produce and apply. Factory marking may require less labor and may be automation-equipment friendly, however the factory marking option may be more costly and more limited in customizability. Plastic inserts, which may be fitted into separate tubes, may be relatively inexpensive but, in some circumstances, a separate piece of marked plastic must be hand-assembled and may only be available for select tubes, such as cryovials. Direct thermal transfer on the surface of the article may have better solvent resistance, but may be available only for selected articles, such as glass HPLC (chromatography) vials, slides, and histology cassettes whose geometry is directly tied to the method for bringing the thermal ribbon to the object to transfer the thermal ink. Any variation in such geometry from manufacturer to manufacturer can cause issues with the loading mechanism.
Moreover, the rigidity of the object must be within a specific tolerance in order to exert sufficient normal force on the ribbon apparatus. Direct thermal transfer also may be relatively expensive and slow due to the use of ribbons. Automated adhesive label appliers may require relatively little labor and may be applicable to a variety of tubes, however, such equipment may be relatively expensive, tube-specific, slow, and may be prone to jamming when the labeled tube is placed into secondary equipment.
Ink-jet inks are fluids that are ejected by a printhead as tiny drops of ink onto a substrate. Although jetting an ink was first proposed by Lord Kelvin in 1867, the first commercial devices were introduced in the 1950s. For many decades, the most popular ink-jet inks were solvent-based inks. A typical solvent is a volatile substance which reacts with the substrate to improve adhesion, but also evaporates to allow for air drying.
Ultraviolet (“UV”) curable inks, on the other hand, do not employ solvents which evaporate. UV inks typically include an acrylic monomer and/or oligomer, pigments, photoinitiators, and other additives. UV inks cure by chemical reaction from the UV light between 200 and 380 nm. A typical UV ink can be cured with less than 1 second of exposure of UV light with sufficient energy (2-8 W/cm2).
There are typically two types of UV curing chemical reactions: free-radical and cationic. In the current state of the art, UV light sources come in two major types, high-intensity mercury arc lamps and UV light emitting diodes (UV-LED). Usually, an ultraviolet light is applied by an ultraviolet light source to an ultraviolet curable ink on a substrate after application of the ink. The ultraviolet light induces a chemical reaction in the ultraviolet curable ink which results in a stronger, cured ink.
UV ink, like most inks, is a pigment dissolved in a carrier. After the ink is ejected onto a substrate, immediately some, but not all, of the solvent evaporates, unlike solvent-based inks where almost all of the solvent evaporates after deposition. A column of very tiny nozzles (100-300 nozzles), each with a droplet of ink is connected to an electronic device. The device can command any particular nozzles to heat up. In the process of heating up, the ink droplet that is near the nozzle's opening will be ejected from the printhead. The substrate is typically strafed across the column of nozzles. As the substrate moves, different sets of nozzles are fired very rapidly (as fast as ten thousand times a second). The combination of selective firing and the movement of the substrate produces a printed image on the substrate.
After the application of the ink to the substrate, it is typically moved under the UV light source. The UV light cures the remaining solvent/pigment ink mixture and sets it into a particular location. That location is the specified text or images specified by the nozzle firing sequence. But before curing, the solvent-pigment mixture can migrate slightly on the substrate. Such migration distorts the accuracy and resolution of the printed image.
The speed with which solvent evaporates before UV curing is correlated to the temperature of the substrate. If the substrate is heated sufficiently, then the heat is transferred to the solvent-pigment which induces more of the solvent to evaporate. If enough solvent has evaporated, the pigment does not have enough of the solvent carrier to migrate far, resulting in a higher quality print result.
Against this backdrop, even with all of the considerations above, due to the very nature of the curved, non-porous substrate printing surface and the properties of the UV curable inks, creating a high-fidelity print on certain lines, shapes, and objects can still be challenging, and the typical print output of a single pass of the print may be significantly improved by repetitive and/or iterative printing on certain portions of said lines, shapes, and objects. The invention takes the advantage of the fact that by identifying certain portions of lines, shapes, and objects for additional iterative printing passes and running additional iterative printing passes on such identified lines, shapes and/or objects, the quality of the printout may be improved.
A method for improving printing quality of a printing apparatus for inkjet printing on cylindrical curved surfaces by iteratively printing multiple layers of UV curable ink on a curved surface. In one possible embodiment, the method is used in the context of a device that is an inkjet printer, comprising a printing rack that holds a plurality of cylindrical objects like test tubes or pipes, a main unit comprising an Ultraviolet (UV) light source and a printing unit assembly. The printing unit assembly holds an ink cartridge further comprising a plurality of ink nozzles and ink reservoir. In one possible embodiment, the printing rack moves the printing objects relative to the main unit. The printing unit preheats the printing objects prior through the use of the UV light source, and after printing the UV light source is used to cure the ink on the surface to produce a high-quality print result.
In a possible embodiment, the inkjet printer has a housing that encloses the main unit, the printing rack, and the printing platform.
The main unit is mounted above the printing platform and printing rack, and the printing rack moves relative to the main unit. In one possible embodiment, the main unit comprises a UV light source and a printing unit.
In one possible embodiment, the UV light source comprises of a plurality of UV LED that can emit UV light that can apply UV radiation to induce a chemical reaction with the ink after printing, but also to apply heat to the print object surface prior to the printing process.
The printing unit comprises of an inkjet cartridge mounting assembly. The inkjet cartridge comprises an ink reservoir and a plurality of nozzles mounted at the bottom portion of the cartridge and dispenses ink through the nozzles during the printing process.
In a possible embodiment, the inkjet printer has a printing platform that can hold a removable printing rack capable of holding a plurality of print objects. The printing rack is designed to hold a plurality of cylindrically shaped print objects organized by rows and columns. For example, if the print object is a small test tube, then the print rack can hold up to several dozens of test tubes at a time. The printing rack can also have numerical labels to help pinpoint the target print object during the printing process.
In a possible embodiment, the printing platform comprises a platform mounted on a pair of rails that can travel laterally and perpendicularly relative to the print unit. In another possible embodiment, the printing platform is a circular track, with the printing rack in the shape of a circular plate, and the printable tubes are placed along the circumference of the circular plate.
In a possible embodiment, the printing device is then typically connected to a computer that can handle print commands and functions through a standard office and/or printing application suite like Microsoft Word, Excel, Acrobat, and the like, or through a customized software.
To print, a user will typically load a number of the printing objects into the removable printing rack and mount the printing rack into the printing platform. The user then inputs the print parameter and command through a computer. Once the user executes the print command, the printing process begins.
In one possible embodiment, the printing process begins by preheating the target print object under the UV-LED unit to heat the surface for several seconds at most. Once the target print object has been heated sufficiently, the target print object is moved underneath the printing unit so the printing unit can dispense ink through the nozzles onto to the surface based on a pattern, text, or image predefined in the printing software. Once the print process completes, the target print object is moved under the UV-LED unit again to cure the ink. The process then repeats itself again for the next target print object until all the target print objects on the rack has been printed. Once the print job is complete, the printing platform returns to the initial position so the user can retrieve the removable rack with the completed printed objects.
In one possible iterative print implementation, after the first print cycle is completed, the software scans the printed image or text and maps each dot it scanned in a 3×3 rectangular array with the scanned dot being in the middle of said rectangular array, and calculates the number of adjacent dots and assigns a score for that dot ranging between zero to eight based on the number of adjacent dots present. The software then makes a copy of the original image, and modifying said copy by removing dots that have a score higher than some desired level. The new image is then sent to the printer, and another print cycle is performed to iteratively print on the surfaces based on the new information and create a higher quality output. This process can be repeated automatically until the desired effect is achieved.
In one possible iterative print implementation, after the first print cycle is completed, a layer of a pigment-free UV ink formulation is printed on top of the image and subsequently cured, thus creating a clear-coat layer that further protects the printed image from smearing, which could happen when the objects are being handled and/or sanitized using chemicals that could potentially react chemically with the ink pigments on the printed image.
The disclosure and the following detailed description of certain embodiments thereof may be understood by reference to the following figures:
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To further illustrate how the scoring system may be implemented, for example, in
Another possible embodiment of the iterative printing is the user manually setting how many iterative prints the machine and software should perform. For example, if the user sets three iterative printing, then the machine and software simply runs the print cycle three times.
In another possible embodiment, a formulation of the UV ink without any pigments (i.e., a clear ink formulation) can be used as a clear-coat layer that is applied after the completion of the printing and curing of the first layer, such that there is an additional layer of clear ink that is printed and cured above the first initial layer to further secure the pigments of the cured ink on the intended location and prevent any unintended smearing and therefore increase the overall quality of the printed text and/or image on the cylindrical surface.
In another possible embodiment, the clear UV-ink coat can be printed on the surface of the substrate below the ink on the first printing pass, similar to a primer coat on a conventional painting process. The primer coat allows for a better adhesion since the glass or plastic substrate is usually an inert material.
The printing sequence is illustrated in
The methods and systems described herein may be deployed in part or in whole through a machine that executes computer software, program codes, and/or instructions on a processor. The processor may be part of a server, client, network infrastructure, mobile computing platform, stationary computing platform, or other computing platform. A processor may be any kind of computational or processing device capable of executing program instructions, codes, binary instructions, and the like. The processor may be or include a signal processor, digital processor, embedded processor, microprocessor, or any variant such as a co-processor (math co-processor, graphic co-processor, communication co-processor and the like) and the like that may directly or indirectly facilitate execution of program code or program instructions stored thereon. In addition, the processor may enable execution of multiple programs, threads, and codes. The threads may be executed simultaneously to enhance the performance of the processor and to facilitate simultaneous operations of the application. By way of implementation, methods, program codes, program instructions and the like described herein may be implemented in one or more thread. The thread may spawn other threads that may have assigned priorities associated with them; the processor may execute these threads based on priority or any other order based on instructions provided in the program code. The processor may include memory that stores methods, codes, instructions, and programs as described herein and elsewhere. The processor may access a storage medium through an interface that may store methods, codes, and instructions as described herein and elsewhere. The storage medium associated with the processor for storing methods, programs, codes, program instructions or other type of instructions capable of being executed by the computing or processing device may include but may not be limited to one or more of a CD-ROM, DVD, memory, hard disk, flash drive, RAM, ROM, cache and the like.
A processor may include one or more cores that may enhance speed and performance of a multiprocessor. In embodiments, the process may be a dual core processor, quad core processors, other chip-level multiprocessor and the like that combine two or more independent cores (called a die).
The methods and systems described herein may be deployed in part or in whole through a machine that executes computer software on a server, client, firewall, gateway, hub, router, or other such computer and/or networking hardware. The software program may be associated with a server that may include a file server, print server, domain server, internet server, intranet server and other variants such as secondary server, host server, distributed server, and the like. The server may include one or more of memories, processors, computer readable media, storage media, ports (physical and virtual), communication devices, and interfaces capable of accessing other servers, clients, machines, and devices through a wired or a wireless medium, and the like. The methods, programs or codes as described herein and elsewhere may be executed by the server. In addition, other devices required for execution of methods as described in this application may be considered as a part of the infrastructure associated with the server.
The server may provide an interface to other devices including, without limitation, clients, other servers, printers, database servers, print servers, file servers, communication servers, distributed servers, and the like. Additionally, this coupling and/or connection may facilitate remote execution of program across the network. The networking of some or all of these devices may facilitate parallel processing of a program or method at one or more location without deviating from the scope of the disclosure. In addition, all the devices attached to the server through an interface may include at least one storage medium capable of storing methods, programs, code and/or instructions. A central repository may provide program instructions to be executed on different devices. In this implementation, the remote repository may act as a storage medium for program code, instructions, and programs.
The software program may be associated with a client that may include a file client, print client, domain client, internet client, intranet client and other variants such as secondary client, host client, distributed client, and the like. The client may include one or more of memories, processors, computer readable media, storage media, ports (physical and virtual), communication devices, and interfaces capable of accessing other clients, servers, machines, and devices through a wired or a wireless medium, and the like. The methods, programs or codes as described herein and elsewhere may be executed by the client. In addition, other devices required for execution of methods as described in this application may be considered as a part of the infrastructure associated with the client.
The client may provide an interface to other devices including, without limitation, servers, other clients, printers, database servers, print servers, file servers, communication servers, distributed servers, and the like. Additionally, this coupling and/or connection may facilitate remote execution of program across the network. The networking of some or all of these devices may facilitate parallel processing of a program or method at one or more location without deviating from the scope of the disclosure. In addition, all the devices attached to the client through an interface may include at least one storage medium capable of storing methods, programs, applications, code and/or instructions. A central repository may provide program instructions to be executed on different devices. In this implementation, the remote repository may act as a storage medium for program code, instructions, and programs.
The methods and systems described herein may be deployed in part or in whole through network infrastructures. The network infrastructure may include elements such as computing devices, servers, routers, hubs, firewalls, clients, personal computers, communication devices, routing devices and other active and passive devices, modules and/or components as known in the art. The computing and/or non-computing device(s) associated with the network infrastructure may include, apart from other components, a storage medium such as flash memory, buffer, stack, RAM, ROM, and the like. The processes, methods, program codes, instructions described herein and elsewhere may be executed by one or more of the network infrastructural elements.
The methods, program codes, and instructions described herein and elsewhere may be implemented on a cellular network having multiple cells. The cellular network may either be frequency division multiple access (FDMA) network or code division multiple access (CDMA) network. The cellular network may include mobile devices, cell sites, base stations, repeaters, antennas, towers, and the like.
The methods, programs codes, and instructions described herein and elsewhere may be implemented on or through mobile devices. The mobile devices may include navigation devices, cell phones, mobile phones, mobile personal digital assistants, laptops, palmtops, netbooks, pagers, electronic books readers, music players and the like. These devices may include, apart from other components, a storage medium such as a flash memory, buffer, RAM, ROM and one or more computing devices. The computing devices associated with mobile devices may be enabled to execute program codes, methods, and instructions stored thereon. Alternatively, the mobile devices may be configured to execute instructions in collaboration with other devices. The mobile devices may communicate with base stations interfaced with servers and configured to execute program codes. The mobile devices may communicate on a peer to peer network, mesh network, or other communications network. The program code may be stored on the storage medium associated with the server and executed by a computing device embedded within the server. The base station may include a computing device and a storage medium. The storage device may store program codes and instructions executed by the computing devices associated with the base station.
The computer software, program codes, and/or instructions may be stored and/or accessed on machine readable media that may include: computer components, devices, and recording media that retain digital data used for computing for some interval of time; semiconductor storage known as random access memory (RAM); mass storage typically for more permanent storage, such as optical discs, forms of magnetic storage like hard disks, tapes, drums, cards and other types; processor registers, cache memory, volatile memory, non-volatile memory; optical storage such as CD, DVD; removable media such as flash memory (e.g. USB sticks or keys), floppy disks, magnetic tape, paper tape, punch cards, standalone RAM disks, Zip drives, removable mass storage, off-line, and the like; other computer memory such as dynamic memory, static memory, read/write storage, mutable storage, read only, random access, sequential access, location addressable, file addressable, content addressable, network attached storage, storage area network, bar codes, magnetic ink, and the like.
The methods and systems described herein may transform physical and/or or intangible items from one state to another. The methods and systems described herein may also transform data representing physical and/or intangible items from one state to another.
The elements described and depicted herein, including in flow charts and block diagrams throughout the figures, imply logical boundaries between the elements. However, according to software or hardware engineering practices, the depicted elements and the functions thereof may be implemented on machines through computer executable media having a processor capable of executing program instructions stored thereon as a monolithic software structure, as standalone software modules, or as modules that employ external routines, code, services, and so forth, or any combination of these, and all such implementations may be within the scope of the present disclosure. Examples of such machines may include, but may not be limited to, personal digital assistants, laptops, personal computers, mobile phones, other handheld computing devices, medical equipment, wired or wireless communication devices, transducers, chips, calculators, satellites, tablet PCs, electronic books, gadgets, electronic devices, devices having artificial intelligence, computing devices, networking equipment, servers, routers and the like. Furthermore, the elements depicted in the flow chart and block diagrams, or any other logical component may be implemented on a machine capable of executing program instructions. Thus, while the foregoing drawings and descriptions set forth functional aspects of the disclosed systems, no particular arrangement of software for implementing these functional aspects should be inferred from these descriptions unless explicitly stated or otherwise clear from the context. Similarly, it will be appreciated that the various steps identified and described above may be varied, and that the order of steps may be adapted to particular applications of the techniques disclosed herein. All such variations and modifications are intended to fall within the scope of this disclosure. As such, the depiction and/or description of an order for various steps should not be understood to require a particular order of execution for those steps, unless required by a particular application, or explicitly stated or otherwise clear from the context.
The methods and/or processes described above, and steps thereof, may be realized in hardware, software or any combination of hardware and software suitable for a particular application. The hardware may include a dedicated computing device or specific computing device or particular aspect or component of a specific computing device. The processes may be realized in one or more microprocessors, microcontrollers, embedded microcontrollers, programmable digital signal processors or other programmable device, along with internal and/or external memory. The processes may also, or instead, be embodied in an application specific integrated circuit, a programmable gate array, programmable array logic, or any other device or combination of devices that may be configured to process electronic signals. It will further be appreciated that one or more of the processes may be realized as a computer executable code capable of being executed on a machine readable medium.
The computer executable code may be created using a structured programming language such as C, an object oriented programming language such as C++, or any other high-level or low-level programming language (including assembly languages, hardware description languages, and database programming languages and technologies) that may be stored, compiled or interpreted to run on one of the above devices, as well as heterogeneous combinations of processors, processor architectures, or combinations of different hardware and software, or any other machine capable of executing program instructions.
Thus, in one aspect, each method described above and combinations thereof may be embodied in computer executable code that, when executing on one or more computing devices, performs the steps thereof. In another aspect, the methods may be embodied in systems that perform the steps thereof, and may be distributed across devices in a number of ways, or all of the functionalities may be integrated into a dedicated, standalone device or other hardware. In another aspect, the means for performing the steps associated with the processes described above may include any of the hardware and/or software described above. All such permutations and combinations are intended to fall within the scope of the present disclosure.
While the invention has been disclosed in connection with the preferred embodiments shown and described in detail, various modifications and improvements thereon will become readily apparent to those skilled in the art. Accordingly, the spirit and scope of the present disclosure is not to be limited by the foregoing examples, but is to be understood in the broadest sense allowable by law.
This Non-Provisional patent application claims the benefit of priority of U.S. Provisional Patent Application No. 63/448,015, filed on Feb. 24, 2023, of which the disclosures are hereby incorporated by reference and to which priority is claimed.
| Number | Date | Country | |
|---|---|---|---|
| 63448015 | Feb 2023 | US |
