Systems and methods for printing a flexible web and printing compositions
A printing system comprises a transport apparatus adapted to transport a flexible web ( 24 ) along a process direction and first and second individually controllable inkjet imager units ( 44, 60, 70, 82 ) offset from one another along the process direction. Each of the first imager unit and the second imager unit includes a first portion ( 226 ) operable to print on a first portion of the web and a second portion ( 228 ) operable to print on the second portion of the web wherein each of the first portion and second portion of the first and second imager units is stationary along the process direction and the lateral direction.
1. A printing system, comprising:
a transport apparatus adapted to transport a flexible web along a process direction;
first and second individually controllable ink jet imager units offset from one another along the process direction wherein each of the first ink jet imager unit and the second ink jet imager unit includes a first portion operable to print on a first portion of the web and a second portion operable to print on the second portion of the web wherein each of the first portion and second portion of the first and second ink jet imager units is stationary along the process direction and the lateral direction and wherein the first ink jet imager unit prints on the web at a first print resolution and the second ink jet imager unit prints on the web at a second print resolution different than the first print resolution;
the second ink jet imager unit comprising a plurality of inkjet printing units disposed around a circumference of a drum;
each inkjet printing unit comprising a plurality of inkjet printheads such that ejection nozzles of the inkjet printheads substantially span the width of the flexible web;
a first closed-loop control system that controls web handling and a distance of at least one of the first portion and the second portion of at least one of the first ink jet imager unit and the second ink jet imager unit from the web; and
a second closed-loop control system that controls registration between the first ink jet imager unit and the second ink jet imager unit.
2. The printing system of claim 1 , wherein the first closed-loop control system includes a printhead position sensor and a printhead actuator.
3. The printing system of claim 1 , further including a plurality of cross-grooved idler rollers that support the web wherein each cross-grooved idler roller comprises two independently journaled portions.
4. The printing system of claim 3 , further including an imaging drum, a nip roller adjacent the imaging drum and forming a nip therewith, and a spreader roller disposed between the plurality of cross-grooved idler rollers and the nip roller.
5. The printing system of claim 4 , wherein each idler roller is disposed no more than a first distance from an adjacent idler roller, spreader roller, and nip roller and wherein the spreader roller is disposed no more than a second distance from the nip, wherein the first distance is in a range of 38 to 28 inches, 36 to 30 inches, or 35 to 33 inches and the second distance is in a range of 6 to 11 inches, 6.5 to 9 inches, or 7.0 to 8.5 inches.
6. A printing system for printing a heat-shrinkable web, comprising:
a transport apparatus adapted to transport a heat shrinkable flexible web along a process direction, the heat-shrinkable flexible web having a total free shrink at 185° F. of at least 20% as measured by ASTM D2732;
first and second individually controllable ink jet imager units offset from one another along the process direction wherein each of the first ink jet imager unit and the second ink jet imager unit includes a first portion operable to print on a first portion of the web and a second portion operable to print on the second portion of the web wherein each of the first portion and second portion of the first and second ink jet imager units is stationary along the process direction and the lateral direction and wherein the first ink jet imager unit includes printheads that print on the web at a first print resolution and the second ink jet imager unit includes printheads that print on the web at a second print resolution different than the first print resolution;
a first closed-loop control system that controls web handling and a distance of at least one of the printheads from the web;
a second closed-loop control system responsive to web temperature that controls print drying without substantial shrinking of the web; and
a third closed-loop control system that controls registration between the first ink jet imager unit and the second ink jet imager unit.
7. The printing system of claim 6 , wherein the first closed-loop control system includes a printhead position sensor and a printhead actuator.
8. The printing system of claim 6 , further including a plurality of cross-grooved idler rollers that support the web wherein each cross-grooved idler roller comprises two independently journaled portions.
9. The printing system of claim 8 , further including an imaging drum, a nip roller adjacent the imaging drum and forming a nip therewith, and a spreader roller disposed between the plurality of cross-grooved idler rollers and the nip roller.
10. The printing system of claim 9 , wherein each idler roller is disposed no more than a first distance from an adjacent idler roller, spreader roller, and nip roller and wherein the spreader roller is disposed no more than a second distance from the nip, wherein the first distance is in a range of 38 to 28 inches, 36 to 30 inches, or 35 to 33 inches and the second distance is in a range of 6 to 11 inches, 6.5 to 9 inches, or 7.0 to 8.5 inches.
11. A printing system for printing a heat-shrinkable web, comprising:
a transport apparatus adapted to transport a flexible heat-shrinkable web along a process direction, the heat-shrinkable flexible web having a total free shrink at 185° F. of at least 20% as measured by ASTM D2732;
first and second individually controllable ink jet imager units offset from one another along the process direction wherein each of the first ink jet imager unit and the second ink jet imager unit includes a first portion operable to print on a first portion of the web and a second portion operable to print on the second portion of the web wherein each of the first portion and second portion of the first and second ink jet imager units is stationary along the process direction and the lateral direction;
at least one dryer operable to dry print on the web without substantial shrinking of the web;
a first closed-loop control system responsive to an indication of web temperature that controls the at least one dryer; and
a second closed-loop control system that controls registration between the first ink jet imager unit and the second ink jet imager unit.
12. The system of claim 11 , further including a distortion corrector that adjusts dimensions of a page element to be printed on the web to compensate for distortion of the printed page element due to shrinking of the web.
13. The system of claim 12 , wherein the distortion corrector includes a customer-site distortion analyzer that analyzes an image of the web having a product disposed therein to adjust distortion parameters.
14. The system of claim 11 , wherein the at least one dryer includes a heater unit associated with and disposed downstream of one of the ink jet imager units and adapted to generate a flow of heated air to heat the web.
15. The system of claim 14 , further comprising a camera disposed downstream of the heater unit, wherein the first closed-loop control system receives an image of the web from the camera, analyzes the received image to detect insufficient drying of material deposited on the web, and in response adjusts operation of the heater unit.
16. The system of claim 11 , wherein the second closed-loop control system is adapted to register first content printed by the first portion of the first ink jet imager unit with content printed by the first portion of the second ink jet imager unit, register content printed by the second portion of the first ink jet imager unit with content printed by the second portion of the second ink jet imager unit, independently control the first portion and the second portion of the first ink jet imager unit, and independently control the first portion and the second portion of the second ink jet imager unit.
17. A printing system for printing a heat-shrinkable web, comprising:
a transport apparatus adapted to transport a flexible heat-shrinkable web along a process direction, the heat-shrinkable flexible web having a total free shrink at 185° F. of at least 20% as measured by ASTM D2732;
first and second individually controllable ink jet imager units offset from one another along the process direction wherein each of the first ink jet imager unit and the second ink jet imager unit includes a first portion operable to print on a first portion of the web and a second portion operable to print on the second portion of the web wherein each of the first portion and second portion of the first and second ink jet imager units is stationary along the process direction and the lateral direction and wherein the first ink jet imager unit prints on the web at a first print resolution and the second ink jet imager unit prints on the web at a second print resolution different than the first print resolution;
at least one dryer operable to dry print on the web without substantial shrinking of the web;
a first closed-loop control system responsive to an indication of web temperature that controls the at least one dryer; and
a second closed-loop control system that controls registration between the first ink jet imager unit and the second ink jet imager unit wherein the second closed-loop control system is adapted to register first content printed by the first portion of the first ink jet imager unit with content printed by the first portion of the second ink jet imager unit, register content printed by the second portion of the first ink jet imager unit with content printed by the second portion of the second ink jet imager unit, independently control the first portion and the second portion of the first ink jet imager unit, and independently control the first portion and the second portion of the ink jet second imager unit.
18. The system of claim 17 , further including a distortion corrector that adjusts dimensions of a page element to be printed on the web to compensate for distortion of the printed page element due to shrinking of the web.
19. The system of claim 18 , wherein the distortion corrector includes a customer-site distortion analyzer that analyzes an image of the web having a product disposed therein to adjust distortion parameters.
20. The system of claim 17 , wherein the at least one dryer includes a heater unit associated with and disposed downstream of one of the ink jet imager units and adapted to generate a flow of heated air to heat the web.
21. The system of claim 20 , further comprising a camera disposed downstream of the heater unit, wherein the first closed-loop control system receives an image of the web from the camera, analyzes the received image to detect insufficient drying of material deposited on the web, and in response adjusts operation of the heater unit.