Continuous motion printing on cylindrical objects
10076915 ยท 2018-09-18
Assignee
Inventors
Cpc classification
B41J3/00
PERFORMING OPERATIONS; TRANSPORTING
B41J2/2132
PERFORMING OPERATIONS; TRANSPORTING
B41J25/00
PERFORMING OPERATIONS; TRANSPORTING
B41J3/4073
PERFORMING OPERATIONS; TRANSPORTING
International classification
B41J3/00
PERFORMING OPERATIONS; TRANSPORTING
B41J25/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A method for printing a digitally-stored image on the surface of a cylindrical object comprises the steps of axially moving the object along a line of travel that is aligned with the object's long axis until it is underneath one or more printheads, each of which have a plurality of ink nozzles that may be arranged in one or more columns while simultaneously rotating the object with respect to the printheads and simultaneously causing a pre-determined number of nozzles to eject ink onto the surface of the object.
Claims
1. A method for printing a multicolor image onto a cylindrical printing area of an object having a longitudinal axis in a single printing pass using an array of printheads located around the longitudinal axis of the object comprising: positioning the nozzles of each printhead in a column aligned with the longitudinal axis of the cylindrical printing area, the nozzles of the printheads being represented as 2x:n, where x is a letter representing one of the printheads of the array and where n is an integer from 1 to an integer representing the number of nozzles in each printhead; advancing the cylindrical printing area along its longitudinal axis while simultaneously rotating it about the axis; firing each of the printhead nozzles twice in succession beginning when the leading edge of the printing area enters the nozzle array to deposit successive color dots at half the nozzle spacing, the firing of the nozzles proceeding in successive sequences each producing successive overlapping helical deposition patterns, the first sequence in which x=a and n=1 comprising firing nozzle 2a followed by nozzles 2b, 2c up to the number of printheads in the array with n being incremented by 1 for each successive printhead in the array; continuing to fire the nozzles as required to deposit color dots over each other in the successive overlapping helical deposition patterns as necessary to complete the image where n increases by 1 in each successive sequence through n=the number of nozzles in each printhead, whereupon n begins again at 1 until the image is completed; and withholding firing of selected printhead nozzles as required by the image.
2. The method of claim 1 in which each of the color dots deposited over each other are overlaid on one another.
3. The method of claim 1 in which each of the color dots deposited over each other is offset from its predecessor.
4. The method of claim 1 in which the rotating of the cylindrical printing area about its longitudinal axis is slowed to ensure that the second fired dots are properly deposited.
5. The method of claim 1 in which each printhead has two adjacent nozzle columns with adjacent nozzles and the adjacent nozzles are fired to deposit successive dots.
6. The method of claim 5 in which alternating adjacent nozzles are fired to print in alternating image columns.
7. The method of claim 5 in which each nozzle of each printhead column is fired a plurality of times in succession such that successive dots are deposited at locations between the nozzle spacing.
8. The method of claim 1 in which each printhead has a plurality of nozzle columns with adjacent nozzles and the adjacent nozzles are fired in succession across the columns.
9. The method of claim 8 in which alternating adjacent nozzles are fired to print in alternate image columns.
10. The method of claim 8 in which each nozzle of each printhead column is fired a plurality of times in succession such that successive dots are deposited at locations between the nozzle spacing.
11. A method for printing a multicolor image onto a cylindrical printing area of an object having a longitudinal axis in a single printing pass using an array of printheads located around the longitudinal axis of the object comprising: positioning the nozzles of each printhead in a column aligned with the longitudinal axis of the cylindrical printing area, each printhead having two adjacent nozzle columns with adjacent nozzles and the adjacent nozzles are fired to deposit successive dots at half the nozzle spacing; the nozzles of the printheads being represented as 2x:n, where x is a letter representing one of the printheads of the array and where n is an integer from 1 to an integer representing the number of nozzles in each printhead; advancing the cylindrical printing area along its longitudinal axis while simultaneously rotating it about the axis; firing each of the printhead nozzles twice in succession beginning when the leading edge of the printing area enters the nozzle array to deposit successive color dots at half the nozzle spacing, the firing of the nozzles proceeding in successive sequences each producing successive overlapping helical deposition patterns, the first sequence in which x=a and n=1 comprising firing nozzle 2a followed by nozzles 2b, 2c up to the number of printheads in the array with n being incremented by 1 for each successive printhead in the array; continuing to fire the nozzles as required to deposit color dots over each other in the successive overlapping helical deposition patterns as necessary to complete the image where n increases by 1 in each successive sequence through n=the number of nozzles in each printhead, whereupon n begins again at 1 until the image is completed; and withholding firing of selected printhead nozzles as required by the image.
12. The method of claim 11 in which each of the color dots deposited over each other are overlaid on one another.
13. The method of claim 11 in which each of the color dots deposited over each other is offset from its predecessor.
14. The method of claim 11 in which the native resolution of each printhead is the space between the printhead nozzles and the native resolution is increased in the axial direction by firing each nozzle of each printhead twice in succession.
15. The method of claim 11 in which the rotating of the cylindrical printing area about its longitudinal axis is slowed to ensure that the second fired dots are properly deposited.
16. The method of claim 11 in which alternating adjacent nozzles are fired to print in alternating image columns.
17. The method of claim 11 in which the native resolution of each printhead is the space between the printhead nozzles in the nozzle columns and the image resolution is increased by firing each nozzle of each printhead column twice in succession such that a second dot is deposited at a location between the nozzle spacing defining the native resolution.
18. The method of claim 11 in which each nozzle of each printhead column is fired a plurality of times in succession such that successive dots are deposited at locations between the nozzle spacing.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The present invention is described with reference to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.
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DETAILED DESCRIPTION
(28) The various embodiments of the present invention and their advantages are best understood by referring to
(29) 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.
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(31) The line defined by 2a:0 through 2d:0 is the start of the nozzle array 402 relative to the advancing object 1. Likewise, the line defined by nozzles 2a:499, 2b:499, 2c:499 and 2d:499 mark the end of the nozzle array 404. The printhead native resolution 403 is the space between nozzles 407.
(32) As described above, colors are deposited on the object surface in order from light colors to dark colors, or from yellow (printhead 2a) to black (printhead 2d). Thus, corresponding nozzles, e.g., 2a:7, 2b:7, 2c:7 and 2d:7 eject ink in that order as the object 1 rotates beneath them. Were the object not advancing along the line of travel, all the nozzles 407 would fire. However, because the object 1 is axially advancing simultaneously with its rotational motion, the resulting deposition pattern is helical about the surface of the object 1 and not every nozzle 407 will be fired. Accordingly, it will be appreciated that in this example, certain nozzles 407 are not used as the object 1 advances and rotates. The number of unused nozzles 407 in each printhead 2a-2d is identical, but their location within each printhead 2 differs. In this example, that number is three per printhead 2a-2d, but the actual number in practice is dependent upon the desired print resolution, printhead 2a-2d native resolution 403, and firing frequency, as well as the axial and rotary motion speeds of the object 1 beneath the printheads 2a-2d, as will be appreciated by those skilled in the relevant arts.
(33) To illustrate this,
(34) After first nozzle 2a:0 of the first printhead 2a deposits its ink, the result of which is a dot on the surface of the object 1, it will be printed over by the second nozzle 2b:1 of the second printhead 2b, the third nozzle 2c:2 of the third printhead 2c and the fourth nozzle 2d:3 of the fourth printhead 2d all of which lay along angled line 406a. In fact, it may be generalized in this example that 2a:x will be printed over by 2b:x+1, 2c:x+2 and 2d:x+3. The nature of printing, and specifically that of process printing, may result in not all positions on the object 1 surface receiving all colors. Alternatively, dots may not be overlaid exactly on one another and a dot may be offset from its predecessor. It can be seen the nozzles 407 that lie within the angle 408a defined between the angled line 406a and the start of the nozzle array 402 are not fired in this scheme.
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(38) Similarly, for the second printhead 2b, the first dot 2b:1 is from the second nozzle 2b:1 doesn't occur until Sequence 2, followed by the second 2b:1 and third 2b:2 nozzles (SEQUENCE 3), then the second 2b:1, third 2b:2 and fourth 2b:3 nozzles (SEQUENCE 4), then the second 2b:1, third 2b:2, fourth 2b:3 and fifth 2b:4 nozzle (not shown) (SEQUENCE 5: not shown), and so on. The first dot 2c:2 to be printed by the third printhead 2c is from the third nozzle 2c:2 (SEQUENCE 3), followed by the third 2c:2 and fourth 2c:3 (SEQUENCE 4), then the third 2c:2, fourth 2c:3 and fifth 2c:4 (not shown) (SEQUENCE 5: not shown), then the third 2c:2, fourth 2c:3, fifth 2c:4 (not shown) and sixth 2c:5 (not shown) (SEQUENCE 6: not shown), and so on. The first dot 2d:3 printed by the fourth printhead 2din this exampleis from the fourth nozzle 2d:3 (SEQUENCE 4), followed by the fourth 2d:3 and fifth 2d:4 (not shown) (SEQUENCE 5: not shown), then the fourth 2d:3, fifth 2d:4 (not shown) and sixth 2d:5 (not shown) (SEQUENCE 6: not shown), and so on. For illustrative purposes,
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(42) The image 601 is subsequently printed along a helix angle ?, which is determined by the horizontal (X) print resolution and axial (Y) resolution and may be found by
?=tan.sup.?1D/C
where C is the circumference of the print area. The image 601 advance distance D, measured in pixels, is a function of the desired print resolution in the axial (Y) direction and is determined by the number, N, of lines (
(43) For example, assuming a cylindrical object comprises a diameter of 2.6 inches, C=2.6??=8.168 in. Circumferential density is roughly 1000 dpi resulting in 8168 pixels per line. To make everything integer multiples, 8192 (pixel divider of 20) pixels may be used. Axial motion may be defined as 1+(L.sub.n?(P?I))?720, where L.sub.n is the number of image lines, P is the desired number of passes or times the object will be passed under the printhead(s), I is the desired multiple of interlacing, e.g., 2? or 4?. 720 is the desired pixel density in the axial direction.
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(45) In this figure, the leading end 401 of the object 1 is starting to the start of the nozzle array 402. It is necessary here to designate certain nozzles the printheads 2a-2d unusable for the same reason as described above with respect to the single nozzle column configuration. In this example, the unused nozzles are 2a:0:497, 2a:0:498, 2a:0:499, 2a:1:497, 2a:1:498, 2a:1:499, 2b:0:0, 2b:1:0, 2b:0:498, 2b:0:499, 2b:1:498, 2b:1:499, 2c:0:0, 2c:0:1, 2c:1:0, 2c:1:1, 2c:0:499, 2c:1:499, 2d:0:0, 2d:0:1, 2d:0:2, 2d:1:0, 2d:1:1, 2d:2:2. The total number of unused nozzles in each printhead 2a-2d is again identical, but their location within the printheads 2a-2d differs. In this example, that number is six per printhead 2a-2d (three in each column), but the actual number in practice is dependent upon the print resolution desired, printhead native resolution 403 and firing frequency, desired axial printhead nozzle interlacing, e.g., 2 times, 4 times, etc., desired circumferential printhead nozzle interlacing, as well as the resultant axial and rotary motion speeds of the object 1 beneath the printheads 2a-2d.
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(51) To achieve interlacing in the axial direction, the object should be advanced in should be an odd number of lines (L1, L3, etc.). However, all advances must be equal. This is an inherent helical motion restriction. To achieve this in the printing system such as that shown and described above, an axial encoder may be slaved to the rotary encoder. The image advance determines the gear ratio between the rotary and axial motion.
(52) In pre-processing, the digital image must be pre-shifted to compensate for the helical angle ?. For example, each column Cn is shifted vertically in the opposite direction, but equal in magnitude corresponding to the helix angle ?. The vertical shift in the Y direction (
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(54) In addition, pixels density, or dots density, should be an integer multiple of the number of revolutions per second or the number of subdivisions of a revolution.
(55) As described above and shown in the associated drawings, the present invention comprises a method for continuous motion printing on cylindrical objects. While particular embodiments have been described, it will be understood, however, that any invention appertaining to the method described 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 invention.