Description:A PRINTING SYSTEM FOR APPLYING PATTERNS AND DESIGNS ONTO AN ALUMINUM COIL

FIELD OF THE INVENTION
[001] Embodiments of the present invention generally relate to a printing system for applying patterns and designs onto an aluminum coil and particularly to a method for printing design on the aluminum coil thereby aiding in achieving a precise pattern with well-defined edges, enhancing the overall quality and aesthetic appeal of the aluminum coil.
DESCRIPTION OF RELATED ARTS
[002] A printing system for aluminum coils is a method of applying a printed design or pattern to aluminum coils, which are commonly employed for ornamental, labeling, or functional purposes in a variety of industries. The rigorous preparation of the aluminum coils begins with extensive cleaning, pre-treatment, and typically a coating application to optimize ink adhesion. The complex printing equipment used, often flexographic or digital printers, is at the heart of the operation, precisely constructed to impart exact and consistent prints onto the aluminum surface. Printing patterns on aluminum coils not only improves the visual appeal but also provides functional and cost-effective advantages, making it a useful choice for a wide range of applications across sectors.
[003] In the traditional domain of aluminum coil printing, the indirect gravure printing process is a significant and time-honored technique. This procedure begins with careful preparation of the aluminum coil, which includes cleaning, pre-treating, and maybe applying a base coat to improve ink adhesion. The fundamental element of this method is the gravure cylinder, an engraved printing plate that showcases the designated pattern or design. The volume and complexity of ink to be transferred are determined by the elaborate carving on this cylinder. Customized ink formulas are rigorously produced to suit the etched pattern. The aluminum coil is accurately guided between the engraved cylinder and a pressure roller as ink is transferred to the engraved cylinder and excess is carefully cleaned away. Under exact pressure, ink is transferred from the etched cells of the cylinder onto the aluminum surface, resulting in the desired design.
[004] While the gravure printing method for aluminum coil patterning is a stalwart in the industry, it does face some inherent limitations. The initial cost of engraving may be particularly high for elaborate or unique patterns, providing a financial obstacle for smaller-scale manufacturing. Furthermore, design changes incur significant costs and effort since changing the engraved cylinder is a laborious and costly endeavor, limiting the agility required to adapt quickly to developing design preferences. It may be difficult to provide uniform ink application and consistent color across the aluminum coil surface, which is controlled by elements such as ink viscosity, cylinder quality, and accurate pressure control during printing. Furthermore, due to the mechanical pressures of the printing process, the engraved cylinders wear and tear with time, demanding periodic maintenance or replacement.
[005] There is thus a need for a system that solves the difficulty that arises in the indirect printing approach while also providing elaborate designs with sharp edges.
SUMMARY OF THE INVENTION
[006] Embodiments in accordance with the present invention provide a printing system for applying patterns and designs onto an aluminum coil. The system includes a primary roller having a plurality of engraved grooves on its outer rounded surface for imprinting preset patterns and designs onto the aluminum coil. The system further includes a secondary roller positioned horizontally near the primary roller to provide support to the primary roller. The system also includes a nozzle situated above the primary coil for supplying printing ink onto the surface of the primary roller. The system also includes a metering blade connected to the primary roller to uniformly fill a plurality of grooves of the primary roller.
[007] Embodiments in accordance with the present invention further provide a method for printing design on the aluminum coil. The method includes arranging the primary and secondary roller in close contact with each other. The primary roller is configured to rotate in a clockwise direction and the secondary roller is configured to rotate in an anti-clockwise direction. The method also includes supplying ink into the plurality of engraved grooves of the primary roller using a nozzle. The method also includes passing the aluminum coil between the primary roller and the secondary roller. The method also includes allowing the primary roller to transfer the engraved design onto the moving aluminum coil. The method also includes collecting the printed aluminum coil for further processing or packing.
[008] Embodiments of the present invention may provide a number of advantages depending on its particular configuration. First, embodiments of the present application provide a method for printing design on the aluminum coil thereby aiding in achieving a precise pattern with well-defined edges, enhancing the overall quality and aesthetic appeal of the aluminum coil.
[009] Next, embodiments of the present application may provide an efficient and relatively fast process of printing patterns on the aluminum coil, enabling high-speed production and reducing lead times, which is essential for meeting tight project deadlines.
[0010] Next, embodiments of the present application may ensure the durability and longevity of the printed pattern on the aluminum coil.
[0011] Next, embodiments of the present application may minimize or eliminate the need for additional post-printing treatments, reducing production time and costs.
[0012] These and other advantages will be apparent from the present application of the embodiments described herein.
[0013] The preceding is a simplified summary to provide an understanding of some embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments. The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The above and still further features and advantages of embodiments of the present invention will become apparent upon consideration of the following detailed description of embodiments thereof, especially when taken in conjunction with the accompanying drawings, and wherein:
[0015] FIG. 1 depicts a system for applying patterns and designs onto an aluminum coil, according to an embodiment of the present invention; and
[0016] FIG. 2 depicts a flowchart of a method for printing designs on the aluminum coil, according to another embodiment of the present invention.
[0017] The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include”, “including”, and “includes” mean including but not limited to. To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures. Optional portions of the figures may be illustrated using dashed or dotted lines, unless the context of usage indicates otherwise.
DETAILED DESCRIPTION
[0018] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.
[0019] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.
[0020] As used herein, the singular forms “a”, “an”, and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.
[0021] FIG. 1 depicts a system 100 for applying patterns and designs onto an aluminum coil 112. The system 100 is designed to print user-defined patterns on aluminum coil 112. It creates elaborate and complex drawings on aluminum coil 112 with ease. A significant component of the system 100 is ensuring constant print quality along the full length of the aluminum coil 112. Furthermore, the system 100 is designed to give a visually pleasing surface, boosting the aesthetics of aluminum-based items. Furthermore, the system 100 is optimized for high-speed production, making it ideal for large-scale production and drastically lowering production time. In the preferred embodiment, the system 100 prints a design or pattern on the pre-coated aluminum coil 112 because the coating improves the surface characteristics, appearance, and performance of the aluminum coil 112. Further, the system 100 is used in flex industries. Moreover, the system 100 comprises two ends: the front end is utilized for inserting the aluminum coil 112 for printing, while the second end is designated for dispensing the printed aluminum coil 112.
[0022] According to an embodiment of the present invention, the system 100 further includes a pair of rollers named a primary roller 102 and a secondary roller 104, a nozzle 106, and a metering blade 108.
[0023] The primary roller 102 may be configured to print desired designs or patterns on the aluminum coil 112. Further, the primary roller 102 mapped with a plurality of engraved grooves 110a-110n (hereafter referred to as the grooves 110) that are installed over its outside rounded surface. These grooves 110 are extremely important in helping the primary roller 102 in engraving designs onto the aluminum coil 112. The primary roller 102 may accommodate numerous design types within the scope of the present invention, including but not limited to circles, squares, rectangles, flowers, birds, animals, and others. This invention's embodiments include all forms of designs or patterns, whether established, related art, or yet to be produced. In the preferred embodiment, the engraved grooves 110 are used to print design on the aluminum coil 112.
[0024] Further, the primary roller 102 may be any type of the roller, for example, but not limited to printing roller, conveyor roller, idler roller, guide roller, rubber roller, offset printing roller, laminating roller, embossing roller, Calander roller, anilox roller, and so forth. Embodiments of the present invention are intended to include or otherwise cover any type of the roller including known, related art, and/or later developed technologies.
[0025] The primary roller 102 in the preferred embodiment is a direct engrave roller. The primary roller 102 may be made of a variety of materials, including but not limited to iron, silver, steel, aluminum, and others. It is worth noting that the size and dimensions of the primary roller 102 are changeable based on the measurements of the aluminum coil 112 needed for printing. Furthermore, the primary roller 102 rotates forward, allowing the aluminum coil 112 to move.
[0026] The secondary roller 104 is built with a specific shore-A hardness to support the primary roller 102 and promote better ink transfer during the printing process. Further, the secondary roller 104 is placed horizontally near the primary roller 102. The secondary roller 104, in the context of the current invention, may be made of a variety of materials, including but not limited to iron, aluminum, rubber, plastic, cloth, silver, steel, glass, and others. This invention's embodiments include all material options, whether existing, related art, or freshly invented. The secondary roller 104 in the preferred embodiment is made of rubber, which provides optimal support to the primary roller 102.
[0027] Further, the secondary roller 104 may be any type of the roller, for example, but not limited to printing roller, conveyor roller, idler roller, guide roller, rubber roller, offset printing roller, laminating roller, embossing roller, Calander roller, anilox roller, and so forth. Embodiments of the present invention are intended to include or otherwise cover any type of the roller including known, related art, and/or later developed technologies. As the secondary roller 104, a Nitrile Butadiene Rubber (NBR) and any high pressure (solvent resistant) rubber backup roller is used in the preferred arrangement.
[0028] Furthermore, to provide optimum support and operation, the size and dimensions of the secondary roller 104 are adapted based on the size of the aluminum coil 112. Further, the secondary roller 104 is engaged with the primary roller 102 via pressure that allows the secondary roller 104 to rotate in the opposite direction as the primary roller 102 during the printing process.
[0029] In this mechanism aluminum coil 112 travel with high line tension over the backup pressure roll or the secondary roller 104 which results the rotation of the secondary roller 104, the primary roller 102 having the sliding mechanism to engage the primary roller 102 to the aluminum coil 112 and apply pressure to the aluminum coil 112 and the secondary roller 104 work as backup and pressure roller.
[0030] Consequently, because of this high pressure engaging the primary roller 102 rotate clockwise and the secondary roller 104 rotate anti-clockwise. In this embodiment, a user is anyone who wants to imprint a certain pattern or design onto the aluminum coil 112.
[0031] A nozzle 106 is situated above the primary roller 102 and is designed to deliver printing ink onto the surface of the primary roller 102. The nozzle 106 is designed exclusively for user-defined ink supply. Further, the nozzle 106 has a nip feeding that allows for exact control over ink supply and distribution. It helps in achieving uniform coverage and accurate dispensing of ink, which is crucial for high-quality printing or coating.
[0032] The metering blade 108 is attached to the primary roller 102 and configured to uniformly fill the grooves 110 with ink. It is designed to fill the dispensed ink into the grooves 110 of the primary roller 102. Furthermore, the metering blade 108 removes extra ink from the primary roller 102, resulting in a precise and regulated ink layer. Further, the metering blade 108 is a thin, flat, and flexible strip constructed of various materials. Within the scope of the current invention, this material may be iron, aluminum, rubber, plastic, steel, cloth, glass, paper, silver, and other materials. This invention's embodiments include all material options, whether existing, related art, or freshly invented. The metering blade 108 is thus an important component in achieving consistent and precise ink transfer onto the surface of primary roller 102.
[0033] In an exemplary scenario, when the nozzle 106 commences the ink dispensing process onto the primary roller 102, there may be a chance that an excessive amount of ink is dispensed. As a result, the metering blade 108 sets specific angles and pressure, efficiently eliminates the extra ink. This movement produces a uniform and controlled ink coating on the surface of the primary roller 102. The pressure and angle are determined by obtaining the appropriate thickness for the ink layer, ensuring an excellent printing outcome.
[0034] FIG. 2 depicts a flowchart 200 of a method for printing designs on the aluminum coil 112, according to an embodiment of the present invention. The method comprises the following steps:
[0035] At 202, the initial setup involves precisely arranging all of the system 100's components. The primary roller 102 and the secondary roller 104 are arranged horizontally next to each other via sliding pressure mechanisms. For initiating the printing process, the user needs to rotate the secondary roller 104 via high tension running the aluminum coil 112 that operates both the rollers 102,104 simultaneously, with the primary roller 102 revolving clockwise and the secondary roller 104 rotating anti-clockwise. This configuration ensures that both rollers 102,104 are moving in a coordinated manner during the printing process.
[0036] At 204, during the component setup, the system 100 activates the nozzle 106 to deliver ink over the surface of the primary roller 102 through a nip feeding. The nozzle 106 in this nip feeding is critical for precise control over the supply and even distribution of ink across the primary roller 102. As a result, the system 100 enables the metering blade 108 to evenly distribute the ink into the engraved grooves 110 of the primary roller 102. Furthermore, the metering blade 108 designed to remove any extra ink from the primary roller 102, ensures a well-regulated ink application procedure. This precise management helps to ensure that the desired patterns are printed on the aluminum coil 112 accurately and consistently.
[0037] At 206, once the ink has been effectively filled into the grooves 110, the user is directed to insert the aluminum coil 112 into the first end of the system 100. After insertion, the forward movement of the primary roller 102 and the backward movement of the secondary roller 104 pull the aluminum coil 112 in a forward direction. Further, the system 100 allows the primary roller 102 to transmit its engraved design onto the moving aluminum coil 112 as the aluminum coil 112 moves. This step ensures that the required pattern is precisely transferred onto the aluminum coil 112 during the printing process.
[0038] At 208, once the printing on the aluminum coil 112 is completed correctly, the resulting printed aluminum coil 112 is carefully gathered and meticulously prepared for further applications. This entails precisely managing the printed aluminum coil 112 and securely packing it to protect its integrity and quality for its intended purposes or future processing. This step signifies the effective completion of the printing process, ensuring that the printed aluminum coil 112 is suitably prepared.
[0039] Overall, the present invention relates to a printing system 100 for applying patterns and designs onto a pre-coated aluminum coil 112. The system 100 may be configured to imprint user-defined patterns on the aluminum coil 112. This system 100's versatility is highlighted by its ability to handle a wide range of patterns, from simple to highly elaborate. To begin the pattern printing on the pre-coated aluminum coil 112, the user arranges the various system 100’s components 100.
[0040] This configuration entails aligning the primary roller 102 and secondary roller 104 in a near-horizontal alignment via pressure mechanisms to ensure a secure fit. In the preferred embodiment, pressure mechanisms with parallel configurations are used. Furthermore, this alignment is made feasible by a seamless integration of the pressure mechanisms linking both rollers 102,104. These mechanisms act as the linchpin, allowing both rollers 102,104 to operate in unison during the printing process. As the printing process begins, the user must exert pressure by adjusting the of the slide mechanism. This action causes the primary roller 102 to spin in a clockwise manner, while the secondary roller 104 duplicates this movement in an anti-clockwise way. This synchronized rotation allows a faultless and consistent pattern application onto the pre-coated aluminum coil 112.
[0041] Further, the system 100 allows a nozzle 106 which has been pre-fed by the user with ink, to begin the ink dispensing process. The ink is accurately dispensed onto the surface of the primary roller 102 by the nozzle 106. The system 100 assists the metering blade 108 in expertly distributing the ink within the grooves 110 found on the outer rounded surface of the primary roller 102. This ensures that the ink is applied evenly and thoroughly.
[0042] Furthermore, the metering blade 108, which ensures an ideal and controlled ink layer, is critical in eliminating any surplus ink that may have been dispensed over the primary roller 102. The user then carefully inserts the pre-coated aluminum coil 112, which is intended for printing, between the in-motion primary roller 102 and the secondary roller 104. The coordinated action of the primary roller 102 forward motion pulls the aluminum coil 112 forward through the rollers 102.
[0043] As a result, the printed aluminum coil 112 emerges from the second end of the system 100. Following that, the printed aluminum coil 112 is efficiently collected from the second end of the system 100 and securely packaged for preservation and eventual use. This packing procedure necessitates extreme caution to preserve the integrity and quality of the printed aluminum coil 112 for future usage.
[0044] Embodiments of the invention are described above with reference to block diagrams and schematic illustrations of methods and systems according to embodiments of the invention. It will be understood that each block of the diagrams and combinations of blocks in the diagrams may be implemented by the standard instructions.
[0045] While the invention has been described in connection with what is presently considered to be the most practical and various embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
[0046] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope the invention is defined in the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements within substantial differences from the literal languages of the claims.
, Claims:CLAIMS
I/We Claim:
1. A printing system (100) for applying patterns and designs onto an aluminum coil (112), the system (100) comprising:
a primary roller (102) having a plurality of engraved grooves (110a-110n) on surface for imprinting preset patterns and designs onto the aluminum coil (112) when fed through one end of the printing system (100);
a secondary roller (104) positioned in close proximity to the primary roller (102), rotating opposite to the primary roller (102),
a nozzle (106) situated above the primary roller (102), the nozzle (106) is configured to supply printing ink onto the surface of the primary roller (102); and
a metering blade (108) connected to the primary roller (102), the metering blade (108) configured to uniformly fill a plurality of the grooves (110a-110n) of the primary roller (102) with an ink dispensed from the nozzle (106).
2. The system (100) as claimed in claim 1, wherein the primary roller (102) is configured to rotate in a clockwise direction to enable forward printing upon the aluminum coil (112).

3. The system (100) as claimed in claim 1, the system (100) is specifically adapted for printing preset patterns and designs onto pre-coated aluminum coils (112).

4. The system (100) as claimed in claim 1, wherein the primary roller (102) comprises a direct engrave roller.

5. The system (100) as claimed in claim 1, wherein the secondary roller (104) comprises a Nitrile Butadiene Rubber (NBR) backup roller or any solvent resistant high pressure rubber.

6. A method (200) for printing design on the aluminum coil (112), the method (200) comprises:
arranging a primary roller (102) and a secondary roller (104) in close contact to each other, wherein the primary roller (102) is configured to rotate in a clockwise direction and the secondary roller (104) is configured to rotate in an anti-clockwise direction;
supplying ink into the plurality of engraved grooves (110a-110n) of the primary roller (102) using a nozzle (106);
passing the aluminum coil (112) in between the primary roller (102) and the secondary roller (104), allowing the primary roller (102) to transfer the engraved design onto the moving aluminum coil (112); and
collecting the printed aluminum coil (112) for further processing or packing.
7. The method (200) as claimed in claim 6, wherein the method (200) comprising utilizing a metering blade (108) to fill the grooves (110a-110n) with ink and remove extra ink from the primary roller (102).

8. The method (200) as claimed in claim 6, wherein the method (200) comprising rotating the primary roller (102) in a clockwise direction to enable forward printing upon the aluminum coil (112).

9. The method (200) as claimed in claim 6, wherein the method (200) comprising printing preset patterns and designs onto pre-coated aluminum coil (112).

10. The method (200) as claimed in claim 6, wherein the primary roller (102) comprises a direct engrave roller and the secondary roller (104) comprises a Nitrile Butadiene Rubber (NBR) backup roller or any solvent resistant high pressure rubber.