Printing plastic containers with digital images

(54) Title: PRINTING PLASTIC CONTAINERS WITH DIGITAL IMAGES (51) Int.CI .: B41F 17/00; B41F 17/08 (30) Unionist Priority: 9/2/2005 US 11 / 219,411, 12/30/2004 US 60 / 640,605 (73) Holder (s): PLASTIPAK PACKAGING, INC.

(72) Inventor (s): RONALD L. UPTERGROVE

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PRINTING PLASTIC CONTAINERS WITH DIGITAL IMAGES [001] The present invention relates to plastic containers that have digital images printed on them, particularly curved plastic containers.

[002] Conventional techniques for printing on curved plastic containers are subject to significant disadvantages. For example, it is difficult to obtain proper registration between colors, and changing images, designs, or wording is costly and time consuming.

[003] Inkjet printing with multiple nozzles is useful for flat surfaces. However, the satisfactory use of multiple nozzles on curved surfaces is difficult.

[004] It would be highly desirable to print a digitally generated image directly onto a plastic container, particularly a curved plastic container, because printing can be done at a reasonable speed and at a reasonable cost.

[005] The present invention provides for printing digital images or indications directly onto a plastic container, particularly a curved plastic container, and performing this task in continuous operation at a reasonable speed and at a reasonable cost. Full-color digital graphic images or indications can be printed directly on containers in multiple areas of the container.

[006] In accordance with the present invention, a series of plastic containers is held firmly, and moved to, and from, a first fingerprint location, and a first digital image is printed on it at the first printing location over a first area. printing on the containers, with the containers being supported by their tops, and by a second position spaced from its top, preferably by its base. Desirably, the containers are moved from the first fingerprint location to a second fingerprint location, and a second digital image is printed on them over a second printing area on the containers, spaced from the first printing area, with the containers held in position by its top and a second area spaced from the top, preferably by its base. The containers are preferably kept under internal pressure while the digital image, or images, are printed on them.

[007] The steps of digital printing of scanned image directly on the

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2/6 plastic container prints digital images directly on a preformed container, for example, on an injection molded or blow molded container, such as polyethylene terephthalate (PET) or high density polyethylene (HDPE). The digital printing operation can print the digital image directly on the plastic container, such as by inkjet through an inkjet print head and on the surface of the container. The ink can be a UV-reactive ink, in which case, after printing the ink, it can be cured by exposure to UV light. It is also possible, for example, to treat the surface of the container before the printing operation, such as by flame treatment, by corona treatment, or by plasma jet treatment.

[008] Other aspects of the present invention will be discussed here below.

[009] The present invention will be more readily understandable by considering the following illustrative drawings, where:

- Figure 1 is a top view of the container conveyor with containers:

Figure 2 is a side view of a container flow configuration, and treatment;

Figure 3 is a side view of an alternative configuration of the container and treatment flow;

Figure 4 is a side view of the container grip assembly; and

Figure 5 is an enlarged side view of an alternative container flow and treatment configuration.

[0010] As can be seen in fig. 1 - 3, a conveyor assembly (10) is provided to move the containers (11) through the treatment procedure in the flow direction (12). The containers (11) enter the conveyor assembly from the feeder conveyor (14) at the container inlet (16) and are attached to the container grip assembly (18). The gripping assembly holds the containers (11) in two separate areas, as shown in figs. 1 and 4, by base support (20) of container and top support (22) of container. It is preferred to keep the container at the top and bottom, although it is possible to employ a top support plus a second support away from it, such as on the side wall. This prevents the containers from moving in any direction except in the direction of the container flow (12). The base bracket (20) and the top bracket

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3/6 (22) are synchronized to maintain the same speed and relationship with each other at all times. Naturally, a commercial operation may have more than one conveyor assembly line.

[0011] As can be seen, particularly in figs. 2 and 3, the containers (11) are curved, such as rounded or oval, and have a container radius or curved portion (24). The path of the container (26) also contains a radius of the portion (28) curved at the first printing position (30) which could be substantially equal to the radius (24) of the container to be printed to facilitate the digital printing operation. [0012] When stapling the container (11) to the container inlet (16), an internal pressure is applied inside the container via air pressure means (32) and pressure line (34) - fig. 4 - through the gripping assembly (18), as for example, through the top support (22). Preferably, a pressure regulator (36) is provided to regulate the air pressure, for example, from 0.86 to 68.9 KPa (0.125 to 10 psi). This internal pressure will be maintained throughout the treatment procedure and provides a consistent distance from the container surface to the inkjet head and / or a consistent contact pressure on the container surface to the ink roller if the jet method is used. indirect ink.

[0013] When the containers enter the portion of the curved or radius path (28) they first pass through a first pre-treatment location (A-1) (see figures 2 and 3). The pre-treatment location will serve to raise the surface energy of the container on the first surface (38) of the container to guarantee the adhesion of the paint to it, such as, for example, a heat treatment or a corona treatment.

[0014] The containers will then move to the first print-area (30) position (B1) in fig. 2 and 3. The containers will then have the first impression applied to the first surface (38) of the container in the printing position (30), which can be a first direct drop at the request of the inkjet head as shown in fig. 3, or an indirect drop in the order of the inkjet pad (40) as shown in fig.

2. UV paint will be applied directly to the first surface (38) of the containers in one step. The inkjet can apply high quality multicolored graphics as desired.

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4/6 [0015] The printed containers will then pass through a first curing station (C-1), which will cure the ink or inks applied in the first printing position (30). This can be a source of ultraviolet light or another method of radiation curing. [0016] The containers (11) then enter a straight section (42) of the container path (26) where they are rotated, for example, by 180^O, to expose the second surface (44) of the containers to the second printing position (46), both by the gripping assembly (18) and by another means for rotation. The second surface (44) of the containers is spaced from the first surface (38) of the containers, desirably an area opposite the first surface (38) of the containers by 180^O each other.

[0017] After rotation, the containers with the first surface (38) of the container having the imprint on it are moved through a second pre-treatment area (A-2) where the surface energy of the container on the second surface (44) of the container is elevated as in the first pre-treatment area (A-1). The containers will then move to the second printing position (46), area (B-2), where the second printing will be performed on the second surface (44) of the containers.

[0018] Similar to the first printing position (30), the printing on the second printing position (46) can be a direct drop on the inkjet head order as shown in fig. 3, or an indirect drop in the order of the inkjet pad (40) as shown in fig. 2. Also, in the second printing position (46), a UV ink will be applied directly to the second surface (44) of the containers in one step, as high quality multicolored graphics, as desired.

[0019] The printed containers will then pass through a second curing station (C-2), which will cure the ink or inks applied in the second printing position. Here again, this can be a source of ultraviolet light or another method of radiation curing.

[0020] The container grab assembly (18) will then release the containers, printed on two sides or two locations and then pass over a conveyor to feed the output, or storage, and return to repeat the cycle.

[0021] In the printing procedure, it is desirable to maintain a plurality of print heads at a constant distance and perpendicularity from the printing surface.

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5/6 non-planar container during the printing process. A plurality of print heads can be desirably hinged during the printing process to maintain a constant distance and perpendicularity from the non-planar container surface. A plurality of sensors can be used to measure the curvature of the non-planar surface, and to control the articulation of the plurality of printheads to maintain constant distance and perpendicularity from the non-planar surface. The print heads and / or container are moved, desirably, at a constant speed relative to the non-planar surface, during the printing process. Also, real-time control is preferably provided to the print control system to determine the relative position of the non-planar surface in the printing process. Appearances already seen provide improved fingerprint on the curved surface of the container.

[0022] Then, for example, as shown in fig. 5, which shows an enlarged view of the first printing position (30), area (B-1), the conveyor system or container path (26) can be straight. The containers (11), with their container radii or curved portions (24), pass under the print heads (50), which are each separately movable, up and down, perpendicular to the flow direction ( 52) of containers, in the direction of movement (54) of the print head, by suitable motor means, such as the articulation device (56). A constant distance, or spacing, between the container surface to be printed and the print heads is thus maintained by the use of a measuring device or sensor (58), such as a laser sensor, which determines the location of the surface to be printed and provides electronic feedback to the hinge device (56) to properly move the print heads. Then, as the containers pass under the print heads, each head can move up or down, as desired, independent of each other, and coordinated to the desired print location. Subsequent processing will proceed in the manner shown in figs. 2 and 3 with a straight container path, desirably rotating the container, and printing on the second printing side.

[0023] Thus, the present invention provides an improved procedure for

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6/6 print digital images or directions directly on a curved plastic container. Processing is continuous and efficient and allows two sides or two areas to be printed efficiently.

[0024] It should be understood that the invention is not limited to the illustrations described and shown here, which are intended to be merely illustrative of the best ways of conducting the invention, and which are susceptible to changes in shape, size, arrangement of parts and details of operation. The invention, on the contrary, is intended to encompass all such modifications, which are within the spirit and scope as defined by the claims.

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