Methods and devices for printing on substrates

Patent metadata

Field	Value
Publication number	US-11945209-B2
Application number	US-202217941706-A
Country	US
Kind code	B2
Filing date	Sep 9, 2022
Priority date	Sep 9, 2021
Publication date	Apr 2, 2024
Grant date	Apr 2, 2024

Abstract

A system for printing on a substrate can comprise a conveyor that is configured to move the substrate along a substrate movement axis. The system can further comprise at least one print head array. Each print head array has a plurality of print heads, each print head having a respective orientation axis. The plurality of print heads can have at least a first print head and a second print head, wherein the orientation axis of the first print head is angularly offset from the orientation axis of the second print head. The first print head can be offset from the second print head along the substrate movement axis.

First claim

What is claimed is:

1. A method comprising:
moving a substrate along a substrate movement axis, wherein the substrate has a surface having a first portion and a second portion, wherein the first portion or a plane tangential thereto is angularly offset from the second portion or a plane tangential thereto,
printing on the first portion and the second portion of the surface of the substrate with at least one print head during a single pass of the substrate along the movement axis,
wherein each print head of the at least one print head comprises a first plurality of nozzles spaced along a respective nozzle row axis,
wherein the respective nozzle row axis of each print head of the at least one print head is oriented at an acute angle relative to the substrate movement axis, and
wherein a plane, that includes the respective nozzle row axis of each print head of the at least one print head and is parallel to the substrate movement axis, is spaced from the substrate movement axis.

2. The method of claim 1 , wherein simultaneously printing on the first portion and the second portion of the surface of the substrate comprises printing with at least one print head array having a plurality of print heads, wherein the plurality of print heads comprises at least a first print head and a second print head, wherein an orientation axis of the first print head is angularly offset from an orientation axis of the second print head, wherein the first print head is offset from the second print head along the substrate movement axis.

3. The method of claim 2 , wherein the at least one print head array comprises a plurality of print head arrays, wherein each print head array of the plurality of print head arrays is offset from each other print head array of the plurality of print head arrays along the substrate movement axis.

4. The method of claim 3 , wherein each print head array of the plurality of print head arrays is configured to print a respective color of ink, wherein a first print head array of the plurality of print head arrays is configured to print a first color of ink, and wherein a second print head array of the plurality of print head arrays is configured to print a second color of ink that is different than the first color of ink.

5. The method of claim 4 , wherein the plurality of print head arrays comprises a first print head array that is configured to print black ink, a second print head array that is configured to print cyan ink, a third print head array that is configured to print yellow ink, and a fourth print head array that is configured to print magenta ink.

6. The method of claim 1 , further comprising dispensing a primer onto the substrate.

7. The method of claim 6 , wherein the primer is configured to alter a surface energy of the substrate.

8. The method of claim 2 , wherein each print head of the plurality of print heads is configured to print on a printing area of the substrate as the substrate passes thereby, wherein the printing area of each print head is no greater than 5 mm from said print head.

9. The method of claim 2 , wherein at least one print head of the plurality of print heads of each print head array of the at least one print head array is configured to print on a curved surface of the substrate.

10. The method of claim 2 , wherein the orientation axis of the first print head is angularly offset from the orientation axis of the second print head by at least 30 degrees.

11. The method of claim 2 , wherein the plurality of print heads of the at least one print head array comprises a third print head, wherein an orientation axis of the third print head is angularly offset from the orientation axis of the first print head and the orientation axis of the second print head, and wherein the third print head is offset from each of the first print head and the second print head along the substrate movement axis.

12. The method of claim 11 , wherein the plurality of print heads of the at least one print head array comprises a fourth print head, wherein an orientation axis of the fourth print head is parallel to the orientation axis of the first print head.

13. The method of claim 1 , further comprising measuring linear travel of the substrate along the substrate movement axis using a material position sensor.

14. The method of claim 1 , further comprising dispensing, by a spray coating station, a coating onto the substrate.

15. The method of claim 14 , further comprising dispensing, by a particle dispenser, particles onto the substrate, wherein the particle dispenser is positioned downstream of the spray coating station so that the particles adhere to the substrate by a coating deposited on the substrate.

16. The method of claim 1 , wherein the substrate comprises a bevel, wherein printing on the substrate comprises printing on the bevel.

17. The method of claim 16 , wherein each print head of the at least one print head comprises a first plurality of nozzles spaced along a respective nozzle row axis, wherein the respective nozzle row axis of each print head of the at least one print head is oriented at an acute angle relative to the substrate movement axis, wherein printing on the bevel comprises printing on the bevel using at least two nozzles of the first plurality of plurality of print nozzles.

18. The method of claim 1 , wherein the substrate is a stair nose.

19. The method of claim 1 , wherein the substrate is decking, wall molding, trim, or a furniture component.

20. The method of claim 1 , further comprising embossing a material on the substrate with an embossing assembly, the embossing assembly comprising:
a band formed into a loop, wherein the band has an embossing surface that defines a pattern; and
at least one press roller that is configured to bias the loop against the substrate.

Assignees

• Shaw Ind Group Inc

Inventors

• Odum Thomas
• Henry James K

Classifications

• B41J2/145

  Arrangement thereof · CPC title

• B41J11/0015

  for treating before, during or after printing or for uniform coating or laminating the copy material before or after printing (selective coating B41J2/2114) · CPC title

• B41F19/02 Primary

  with embossing · CPC title

• B41J25/001

  Mechanisms for bodily moving print heads or carriages parallel to the paper surface · CPC title

• B41J25/308

  with print gap adjustment mechanisms · CPC title