Patent Publication Number: US-2022227143-A1

Title: Printing machine and method for changing a color sequence within a printing process

Description:
The invention relates to a printing machine, like for example label printing machine and machine for printing flexible packaging, for printing on a substrate having the form of a web. The printing machine comprises a web entry unit for receiving the web on which a printing process is to be performed and a web exit unit for dispensing the web after the printing process. Moreover, at least two printing units are provided, wherein each of the printing units is configured for applying an ink of a predetermined color on the web. 
     The invention is additionally directed to a method for changing a color sequence within a printing process, especially a label printing process, performed by a printing machine configured for printing on a substrate having the form of a web and comprising at least two printing units, wherein each of the printing units is configured for applying an ink of a predetermined color on the web. 
     Such printing machines are known in the art. In this context, a substrate having the form of a web is to be seen in contrast to a substrate having the form of a sheet. Sheets are discrete portions of substrate, wherein a web often is described as being endless. 
     In the fields of labels applications are known in which a substrate having a printed image on it is used in the final product such that the substrate forms a base and the printed image forms an outside. Consequently, the substrate is behind the printed image. This is for example the case for so-called wrap-around labels which may be glued onto a product or a packaging. The substrate may be transparent or metallized. 
     Alternatively, the substrate with the printed image may be used in the final product such that the substrate forms an outside and the printed image is only visible through the substrate, i.e. the printed image is behind the substrate. This is for example the case for shrink sleeve labels or flexible packaging films. 
     The above alternatives may require that the colors be printed on the substrate in a different sequence. This can best be understood when considering the color white. In cases where the substrate is behind the printed image, the white color is applied as a first color and the remaining colors are printed on top of the white color. This leads to a printed image of high quality, wherein the colors appear in the desired tone. However, in cases where the printed image is behind the substrate, the white color needs to be applied as last color such that, wherever suitable, the remaining colors may appear on a white background. 
     Known printing machines usually provide a fixed sequence of the printing units. Consequently, using the above example, a known printing machine is either suitable for printing white as a first color or for printing white as a last color. Thus, two printing machines are necessary for covering both of the above mentioned alternatives. Alternatively two or more different printing units for printing white could be installed (one at the beginning and one at the end of the printing sequence). 
     The problem to be solved by the invention is, thus, to provide a more flexible printing machine. The printing machine shall especially be able to print colors in differing sequences. 
     The problem is solved by a printing machine of the type mentioned above, wherein at least two web paths are provided between the web entry unit and the web exit unit. Each of the web paths passes by all of the printing units, wherein the web paths pass by the printing units in a differing sequence and whereas a travelling direction of the web remains the same. Consequently, the sequence by which the colors associated with the respective printing units are applied to the substrate may be determined by choosing the appropriate web path. Preferably, the web paths are alternatives. Thus, within the printing machine, the web can only be arranged along one of the web paths at a time. However, this does not exclude that the web paths have common portions. As the travelling direction of the web remains the same, the unwind and rewind unit also remain. Such a printing machine is able to print on the substrate by having the printed image on a front side of the substrate and having the printed image on a back side of the substrate, i.e. the substrate may be in front or behind the printed image in the final product. More generally, such a printing machine is very flexible. It may especially replace two printing machines being adapted for printing fixed, but different color sequences. 
     The printing machine according to the invention is able to print the web on different paths through the machine in one travelling direction and without necessarily modifying the printing machine. The different web paths are provided by different web-in. Such a machine may be able to accommodate also further inline converting modules/units, like e.g. a die-cutting or a flexo-unit for another application (e.g. cold foil). These modules/units need to be passed by the web after being printed. This is not possible in machines where the travelling direction is changed. 
     As the travelling direction remains unchanged in the printing machine, also the color sequence can remain. If the travelling direction of the web is changed, in one direction CMYK is printed and in the other direction KYMC is printed. Depending on the image, this can result in different colors (printing color on top of each other). 
     According to the invention it is possible to not change the color ink sequence by changing the web path. 
     The change of the web path might for example allow to web-in to first print white and then printing the colors or with a different web-in to first print the colors and then printing white on top. 
     According to the invention it is possible, that the machine remains the same and no changes on the machine are necessary, only the web will be pulled in differently and the travelling direction of the web always remains the same. 
     All of the printing units may be arranged along a substantially straight or arched line. This leads to a simple and compact structure of the printing machine. Such a printing machine may be easily maintained since the printing units provide good accessibility. Furthermore, it can be produced with comparatively low efforts. 
     Moreover, all of the at least two printing unit may have a respective front side and a respective backside being arranged opposite the front side. Preferably, the printing units are configured for dispensing ink from the respective front side and all front sides are oriented towards a process space of the printing machine. This means that all front sides are substantially oriented in the same direction. Such a printing machine has a simple and well-arranged structure. This is advantageous during production and maintenance of the printing machine. 
     According to a variant, the entry unit and the exit unit are arranged on the same side of the printing units. Thus, the printing machine is compact. 
     The entry unit of a printing machine according to the invention may comprise a roller assembly for providing the printing process being performed inside the printing machine with web at an appropriate, e.g. constant, speed and with an appropriate tension. 
     Accordingly, also the exit unit of a printing machine according to the invention may comprise a roller assembly for dispensing the web from the printing machine at an appropriate, e.g. constant, speed and with an appropriate tension. 
     It is possible that a gap is located between the printing units, wherein only a first one of the at least two web paths comprises a portion extending through the gap. This means that a second one of the at least two web paths does not pass through the gap. As a result of this configuration the web path passing through the gap can pass around one of the at least two printing unit at the respective backside and then interact with the front side of the remaining printing unit. This is an easy way for providing alternative web paths. Moreover, web paths created in this way may be arranged in close proximity to one another and to the parts of the printing machine, e.g. the printing units. This leads to a compact design of the printing machine. 
     The first one of the at least two web paths may, along its travelling direction, extend through the gap, subsequently pass by a second one of the printing units and subsequently pass by a first one of the printing units. It is understood that the printing units may apply an ink to a substrate passing by them. Consequently, ink of a color provided by the second one of the printing units may be applied on the substrate before ink of a color provided by the first one of the printing units is applied thereto. In other words, a first color sequence is provided. 
     Additionally, the first one of the at least two web paths, along its travelling direction, may extend through the gap after having passed by the first one of the printing units. Thus, the first web path extends twice through the gap. This configuration facilitates the provision of alternative color sequences. 
     In an embodiment, a second one of the at least two web paths, along its travelling direction, passes by a first one of the printing units and subsequently passes by a second one of the printing units. Again, it is understood that the printing units may apply an ink to a substrate passing by them. Consequently, ink of a color provided by the first one of the printing units may be applied on the substrate before ink of a color provided by the second one of the printing units is applied thereto. In other words, a second, alternative color sequence is provided. 
     The printing units may be ink jet printing units or laser printing units. This means that the printing units operate according to the ink jet principle or the laser printing principle. Both technologies can be used for creating high quality prints at comparatively low costs. 
     A printing machine having an ink jet printing unit or a laser printing unit may be designated a digital printing machine since the image to be printed may be transferred directly from a file or data stream from a computer device to the printing machine. Printing forms of any sort are not necessary. Consequently, digital printing machines are especially suitable for printing jobs of small lot sizes. 
     In an alternative, at least one pinning unit is provided. In particular, the pinning unit is arranged adjacent to one of the printing units. An ink may be pre-cured by such a pinning unit. Consequently, ink applied to the substrate by one of the printing units is partly, e.g. surface cured before ink of another one of the printing units is applied to the substrate. This leads to an improved quality of the printed image. If ultraviolet (UV) light curable ink is used, the pinning unit may comprise a pinning lamp for applying a dose of UV light thereto. 
     In this context, at least two coupling units for mounting the pinning unit within the printing machine may be provided, wherein the pinning unit may be selectively coupled to any one of the coupling units. Thus, depending on the printing job to be performed, the pinning unit can be provided at an appropriate location within the printing machine. This leads to high quality printing results. It is understood that also more than two coupling units and thus more than two alternative locations for the pinning unit may be provided. 
     In an embodiment, at least three printing units are provided, being subdivided into two printing unit groups, wherein the at least two web paths pass by the at least two printing unit groups in a differing sequence. Such a configuration is especially useful, if alternative sequences with respect to a single color or a group of colors need to be provided. It is noted that a printing unit group comprises at least one printing unit. 
     For example, five printing units are provided. Each printing unit is adapted for applying ink of one specific color on the substrate. The printing units may be adapted for printing the colors cyan, magenta, yellow, black and white. The printing units adapted for printing cyan, magenta, yellow and black may form a first group. Since the color black often is designated as key, the colors being printable by the first group may be abbreviated as CMYK. The printing unit adapted for printing white color ink forms the second group. In this configuration a first web path passes by the printing units CMYK first and subsequently by the printing unit adapted for printing white ink. A second, alternative web path passes by the printing unit adapted for printing white ink first and then passes by the printing units CMYK. 
     In another example, seven printing units are provided. Printing units being adapted for printing the colors orange, violet, cyan, magenta, yellow and black respectively form a first printing unit group. This group may be designated OVCMYK using the respective first letters of the colors wherein black is termed key. A second group may again be formed by a printing unit being adapted for applying white ink on the substrate. In this configuration a first web path passes by the printing units OVCMYK first and subsequently by the printing unit adapted for printing white ink. A second, alternative web path passes by the printing unit adapted for printing white ink first and then passes by the printing units OVCMYK. 
     In both of the above examples, the first path is well adapted for so-called direct prints on e.g. transparent or metallized substrates being used as labels. The second path is well adapted for printing shrink sleeve labels or flexible packaging films wherein the final image is visible through the transparent substrate. 
     It is noted that it would theoretically also be possible to provide two white printing units within the printing machine, wherein along a web path one is arranged in front of the remaining colors and the other one is arranged behind the remaining colors. During operation of the printing machine only one of these white printing units is active. Consequently, white color could selectively be printed as first or last color. However, such a solution is far more expensive than the solution using two alternative web paths as described above. 
     The printing machine may comprise a curing unit, wherein the curing unit is arranged between the at least two printing units and the web exit unit in respect of all of the web paths. Consequently, a substrate with a well-cured ink will leave the printing machine. The curing unit is for example an UV curing unit or a heat curing unit. 
     Preferably, each of the printing units has a single, fixed position within the printing machine. Thus, the printing units are neither movable nor are alternative positions provided for the printing units. Consequently, the printing units may be fixedly mounted on a machine frame or housing. Such a printing machine is structurally simple, reliable in operation and compact in design. 
     Advantageously, the printing machine comprises one single printing unit per color. This also leads to structural simplicity. 
     The problem is also solved by a method for changing a color sequence within a printing process as mentioned above, wherein the web is arranged along an alternative web path passing by the printing units in a differing sequence. It is noted that the method is a method for changing a color sequence. This means that a starting point for the method is a given color sequence which is realized by a given web path passing by the printing units. This method can be performed in a relatively short amount of time such that a printing machine can be flexibly used as far as the sequence of colors is concerned. 
    
    
     
       The invention will now be explained with reference to two embodiments which are shown in the attached drawings. In the drawings, 
         FIG. 1  shows a printing machine according to the invention, wherein a method according to the invention can be performed with this printing machine, and 
         FIG. 2  shows a slightly modified printing machine according to the invention, wherein also in connection with the slightly modified printing machine a method according to the invention can be performed. 
     
    
    
       FIG. 1  shows a printing machine  10  which is configured as a label printing machine. 
     Furthermore, the printing machine is configured for printing on a substrate having the form of a web  12 . 
     The printing machine  10  comprises a web entry unit  14  for receiving the web  12  on which a printing process is to be performed. 
     The web entry unit  14  has an entry roller  16  and two auxiliary entry rollers  18   a ,  18   b.    
     The entry roller  16  and the auxiliary entry rollers  18   a ,  18   b  are rotatable around respective axes of rotation which are arranged in parallel. 
     In the example shown the auxiliary entry rollers  18   a ,  18   b  are arranged below the entry roller  16 . This is one possibility, but the entry rollers or at least one of them could be also be arranged above the entry roller according to another embodiment. The auxiliary rollers mainly have the function to have a good wrapping of the entry roller, to avoid any slipping of the substrate on the roller and so to ensure a stable web tension. 
     Moreover, auxiliary entry roller  18   a  is arranged on a first lateral side of an axis  16   a  of rotation of the entry roller  16  wherein auxiliary entry roller  18   b  is arranged on a second lateral side of the axis  16   a  of rotation. The second lateral side is opposed to the first lateral side. 
     The printing machine  10  also comprises a web exit unit  20  for dispensing the web  12  after the printing process. 
     The web exit unit  20  is configured in a similar manner as the web entry unit  14 . 
     It comprises an exit roller  22  being rotatable around a corresponding axis  22   a  of rotation. 
     Furthermore, two auxiliary exit rollers  24   a ,  24   b  are provided. 
     The auxiliary exit rollers  24   a ,  24   b  are rotatable around respective axes of rotation which are arranged in parallel to the axis  22   a  of rotation of the exit roller  22 . 
     In the example shown the auxiliary exit rollers  24   a ,  24   b  are arranged below the exit roller  22 . Moreover, the auxiliary exit roller  24   a  is arranged on a first lateral side of the axis  22   a  of rotation of the exit roller  22  and the auxiliary exit roller  24   b  is arranged on a second lateral side of the axis  22   a  of rotation. The second lateral side is opposed to the first lateral side. 
     Additionally, the printing machine  10  comprises a total of seven printing units being designated by reference signs  26  to  38 . 
     Printing unit  26  is configured for applying an ink of white color on the web  12 . Consequently the printing unit  26  is also designated a white printing unit or by the letter W. 
     Printing unit  28  is configured for applying an ink of orange color on the web  12 . Thus, the printing unit  28  is also designated an orange printing unit or by the letter O. 
     Printing unit  30  is configured for applying an ink of violet color on the web  12 . Accordingly, the printing unit  30  is also designated a violet printing unit or by the letter V. 
     Printing unit  32  is configured for applying an ink of cyan color on the web  12 . The printing unit  32  is also designated a cyan printing unit or by the letter C. 
     Printing unit  34  is configured for applying an ink of magenta color on the web  12 . Consequently the printing unit  34  is also designated a magenta printing unit or by the letter M. 
     Printing unit  36  is configured for applying an ink of yellow color on the web  12 . Therefore, the printing unit  36  is also designated a yellow printing unit or by the letter Y. 
     Printing unit  38  is configured for applying black ink on the web  12 . Thus, the printing unit  38  is also designated a black printing unit or by the letter K. This designation is due to the fact that black ink often is also called key. 
     Consequently, the printing machine  10  comprises one single printing unit  26  to  38  per color. 
     The color sequence of the print section as described by example could also be different. The example is described by using OV-CMYK, but all other combinations are possible, e.g. also CMYK-OV. 
     In the examples shown in the figures, the printing units  26  to  38  are ink jet printing units. 
     Furthermore, all printing units  26  to  38  are arranged along a slightly arched line  40 . 
     Each of the printing units  26  to  38  has a single, fixed position along this line  40  and thus within the printing machine  10 . 
     Moreover, the respective front sides of the printing units  26  to  38 , i.e. the sides from which the printing units  26  to  38  may apply ink to the web  12  are all oriented towards the same side, in the example shown a lower side of the printing machine  10 . 
     Furthermore, printing units  28  and  30  are arranged adjacent to one another and form a first printing unit pair. 
     In an analogous manner, printing units  32  and  34  are arranged adjacent to one another and form a second printing unit pair. 
     Also printing units  36  and  38  are arranged adjacent to one another. They form a third printing unit pair. 
     Printing unit  26  is not paired with another one of the printing units  28  to  38 . 
     Furthermore, a gap  42  is provided between the printing unit  26  and the first printing unit pair, more precisely the printing unit  28 . This gap  42  is configured such that the web  12  may pass therethrough as will be explained below. 
     The gap  42  also separates the printing units  26  to  38  into two printing unit groups, wherein a first printing unit group is formed by printing units  28  to  38  and a second printing unit group is formed by printing unit  26 . 
     It is noted that also between the printing units  30  and  32  as well as between the printing units  34  and  36  a certain spacing is provided. However, this spacing is considerably smaller than the gap  42 . As will be explained later, the web  12  does not extend through these spacings. Thus, the spacings will not be designated as gaps. 
     In the configuration of the printing machine  10  as shown in the Figures, the printing units  26  to  38  are arranged above the entry unit  14  and the exit unit  20 . In other words, the entry unit  14  and the exit unit  20  are arranged on the same side of the printing units  26  to  28  which is a lower side in the examples shown. 
     The printing machine  10  also comprises a pinning unit  44 . The pinning unit  44  is used for pre-curing ink applied to the web  12 . 
     In the example of  FIG. 1  the pinning unit  44  is arranged adjacent to printing unit  26 . 
     The printing machine  10  is also equipped with a curing unit  46 . 
     The curing unit  46  comprises a supporting roller  48  which is optionally chilled and a curing energy source  50 . 
     In the examples shown, the curing energy source  50  comprises a UV light source configured for curing UV light sensitive inks. 
     Moreover, within the printing machine  10  two alternative web paths A, B are provided between the web entry unit  14  and the web exit unit  20 . 
     A first web path A along which the web  12  may travel through the printing machine  10  starts at the entry unit  14  where the web  12  is wound around the first auxiliary entry roller  18 , the entry roller  16  and the second auxiliary entry roller  18   b.    
     Thereafter, the web path A extends to a first deviating roller  52  which is generally arranged above the entry unit  14 . 
     The first deviating roller  52  is also arranged at a backside of the printing units  26  to  38 , i.e. above the printing units  26  to  38 . 
     From there, the first web path A extends through the gap  42  to a second deviating roller  54  being arranged at an end of the gap  42 . 
     In doing so, the first web path A has circumvented the printing unit  26  at its backside. 
     The first web path A continues to pass by the printing units  28  to  38  at a respective front side thereof until it reaches a third deviating roller  56 . 
     In between the deviating rollers  54  and  56 , the web  12  travelling along the first web path A is supported by a total of three supporting rollers  58   a ,  58   b ,  58   c.    
     Using deviating rollers  54  and  56  and supporting rollers  58   a ,  58   b ,  58   c  the web  12  travelling along the first web path A is precisely positioned with respect to the printing units  28  to  38 . 
     The first web path A further extends from the third deviating roller  56  to a fourth deviating roller  60  which is substantially arranged below the curing unit  46 . 
     From there it continues to a fifth deviating roller  62  and further to a sixth deviating roller  64 . 
     The portion of the first web path A extending between the fifth deviating roller  62  and the sixth deviating roller  64  passes by the front side of the printing unit  26  and by the pinning unit  44  which is arranged adjacent to the printing unit  26 . 
     Consequently, white ink can be applied to the web  12  and pre-cured by the pinning unit  44 . 
     After that, the first web path A continues to the curing unit  46 , more precisely to the supporting roller  48 . 
     The ink applied to the web  12  by the printing units  26  to  38  can now be fully cured. 
     From the supporting roller  48 , the first web path A extends over a seventh deviating roller  66  and an eights deviating roller  68  to a ninth deviating roller  70 . 
     Thereafter, it passes again through the gap  42  until it reaches a tenth deviating roller  72 . 
     Subsequently, the first web path A extends to the exit unit  20 . 
     Since the first web path A first passes by the printing units  28  to  38 , i.e. by the printing units being adapted for applying ink of orange, violet, cyan, magenta, yellow and black color to the web  12  and subsequently passes by printing unit  26 , which is adapted for applying white ink to the web, the first web path A may also be designated as a “white last” path. 
     As an alternative to the first web path A a second web path B is provided. 
     The second web path B also starts at the entry unit  14  where the web  12  is wound around the first auxiliary entry roller  18   a , the entry roller  16  and the second auxiliary entry roller  18   b.    
     From there it directly extends to the fifth deviating roller  62  and subsequently travels along the front sides of all printing units  26  to  38  until it reaches the third deviating roller  56 . 
     During its travel along the printing units  26  to  38 , the second web path B is supported by the sixth deviating roller  64  and the support rollers  58   a  to  58   c.    
     Consequently, the web  12  travelling along the second web path B will receive white ink first. Subsequently, it may receive ink of the colors orange, violet, cyan, magenta, yellow and black. 
     Thus, the second web path may be called a “white first” path. 
     Again, the white ink is pre-cured by the pinning unit  44  being arranged adjacent to the printing unit  26 . 
     From the third deviating roller  56  the second web path B extends over the fourth deviating roller  60  and the seventh deviating roller  66  until it reaches the curing unit  46 , more precisely the supporting roller  48 . 
     After having passed the supporting roller  48  it reaches the exit unit  20  via the eights deviating roller  68 , the ninth deviating roller  70  and an eleventh deviating roller  74 . 
     It can be seen from the above explanations that each of the web paths A, B passes by all of the printing units  26  to  38 . Consequently, independent from the web path A, B used, all colors may be printed on the web  12 . 
     However, the sequences by which the printing units  26  to  38  are passed differ. 
     In the present example, in which the printing units  26  to  38  are subdivided into a first printing unit group and a second printing unit group, the differing sequence also applies to these printing unit groups. 
     It is noted that in this context only the first web path A comprises a portion extending through the gap  42 . 
     Furthermore, along both web paths A, B the curing unit  46  is arranged between the printing units  26  to  38  and the web exit unit  20 . 
     In  FIG. 2  a second example of the printing machine  10  is shown. 
     The printing machine  10  according to the second example only differs from the printing machine  10  according to the first example in that two coupling units  76 ,  78  for mounting the pinning unit  44  within the printing machine  10  are provided. 
     Thus, the pinning unit  44  may selectively be coupled to one of the coupling units  76 ,  78 . 
     In other words, depending on the printing job to be performed and on the web path A, B used the pinning unit  44  can either be arranged adjacent to the printing unit  26  via coupling unit  76  or adjacent to the printing unit  28  via coupling unit  78 . 
     A method for changing a color sequence within a printing process can be performed in connection with both examples of the printing machine  10 . 
     This method starts form a given color sequence within a printing process which is for example determined in that the web  12  is arranged within the printing machine  10  such that it travels along the first web path A. 
     In order to change the color sequence, the web  12  will be re-arranged to the second web path B. 
     The same applies if the method starts from a given color sequence being determined in that the web  12  is arranged along the second web path B. Then, the web  12  will be re-arranged to the first web path A. 
     In connection with the above examples the web paths A, B with differing color sequences have been explained using the printing unit  26  being configured for applying white ink to the substrate as an example. However, it is clear that a change in color sequence can also be performed with respect to any other color or group of colors. To this end, for example the position of the gap  42  can altered.