CN111867840B

CN111867840B - Method and apparatus for decorating metal containers by digital printing onto transfer blankets

Info

Publication number: CN111867840B
Application number: CN201980018673.0A
Authority: CN
Inventors: A.P.S.斯托维茨
Original assignee: Ball Corp
Current assignee: Ball Corp
Priority date: 2018-02-09
Filing date: 2019-02-08
Publication date: 2022-05-17
Anticipated expiration: 2039-02-08
Also published as: IL276527A; WO2019157346A3; MX2020008172A; EP3749522A4; AU2019216765A1; CN111867840A; AU2019216765B2; RU2757163C1; WO2019157346A2; CA3090266A1; BR112020015545A2; CA3090266C; EP3749522A2

Abstract

An apparatus and method for decorating a metal container with an image or indicia on a predetermined portion of the outer surface of the container body is provided. The decorator includes at least one digital print unit, a transfer blanket, and a support member. The digital printing unit transfers the decor material to the transfer blanket to form a decor on the transfer blanket. Then, the support member moves the metal container into contact with the transfer felt to transfer the decorating material onto the outer surface portion of the metal container, thereby decorating the metal container. In one embodiment, the digital printing unit is an electrophotographic system that transfers toner material to a transfer blanket. In another embodiment, the digital printing unit includes an inkjet print head that transfers ink to a transfer blanket. Alternatively, the decorator may comprise two or more support elements.

Description

Method and apparatus for decorating metal containers by digital printing onto transfer blankets

Reference to related applications

The present application claims the benefit and priority of U.S. patent application 15/893,364 filed on 9/2/2018, U.S. patent application 15/893,364 is a partial continuation of U.S. patent application 15/674,363 filed on 10/8/2017, and claims the benefit and priority of U.S. patent application 15/674,363, and U.S. patent application 15/674,363 claims the priority of U.S. patent application 62/373,134 entitled "method and apparatus for decorating metal containers by digital printing onto a transfer blanket" filed on 10/8/2016 according to the provisions of 35U.S. c., § 119(e), the contents of which are incorporated herein by reference in their entirety.

Technical Field

The present invention relates generally to decorating containers. More specifically, the present invention provides a new apparatus and method for forming a decoration on a transfer blanket using a digital printing unit. The transfer blanket is then contacted with an outer surface portion of the metal container and the decoration is transferred to the outer surface of the metal container.

Background

Metal beverage containers provide many benefits to both merchants and consumers. The metal body of the beverage container provides the best protection for the product. For example, the metal body prevents carbon dioxide migration and transmission of ultraviolet radiation, which can damage the beverage and adversely affect the taste, appearance or color of the product. Metal beverage containers also provide a barrier to light, moisture, grease, oxygen, and microorganisms, and keep the contents of the container fresh and free from external influences, thereby ensuring a long shelf life. The surface of the metal container is also well suited for decoration with trademarks, logos, designs, product information, and/or other preferred indicia to identify, sell, and distinguish the metal container and its contents from other products and competitors. Thus, metal containers provide filling plants, distributors, and retailers the ability to stand out at the point of sale.

Metal beverage containers have better durability than glass containers, which can reduce the number of containers damaged during handling and shipping, thereby further saving costs. In addition, metal beverage containers of comparable size are lighter than glass containers, thereby saving energy consumption during transportation. Moreover, metal beverage containers are capable of withstanding very high burst pressures, which makes them ideal and safe for use as containers containing pressurized products (e.g., containers for carbonated beverages and aerosol products).

In addition, many consumers prefer metal containers over containers made of glass or plastic. Metal containers are particularly attractive to consumers for their convenience. Metal containers are lightweight, which makes them more portable than glass containers. Metal containers are particularly suitable for use in public and outdoors as they are more durable than glass containers. In addition, some consumers avoid using plastic containers due to concerns that plastic may cause chemicals to leach into the consumer product.

Because of these advantages, the worldwide sales of metal containers in 2014 were approximately $ 530 billion. A large portion of the metal container market is driven by beverage containers. According to one report, 2900 million metal beverage containers were sold around the globe in 2012. One american trade group reported that 1260 million metal containers were sold in 2014 in the united states alone. To meet this demand, metal container manufacturing facilities operate some of the fastest (if not the fastest) production lines in the container industry. Due to the high speed of container lines, the techniques or processes that are available in other industries or used in conjunction with containers formed of other materials do not necessarily work at the high speeds required by metal container lines. Thus, many operations for forming and decorating metal containers often require specialized equipment and techniques.

Metal containers are often decorated with images or indicia, such as brand names, logos, product information, or designs, by contact printing methods (e.g., lithographic or offset printing processes). In us 3,766,851, us 3,960,073; us patent 4,384,518; us patent 6,550,389; us patent 6,899,998; U.S. patent application publication 2012/0272846; U.S. patent application publication 2014/0360394; U.S. patent application publication 2015/0183211; U.S. patent application publication 2015/0217559; WIPO publication WO 2013/113616; WIPO publication WO 2014/006517; WIPO publication WO 2014/008544; WIPO publication WO 2014/108489; and contact printing methods and apparatus are described in WIPO publication WO 2014/128200, the contents of which are incorporated herein by reference in their entirety.

Alternatively, the metal container may be decorated by a non-contact printing process. Non-contact printing processes are generally described in U.S. patent 5,018,640, U.S. patent 6,769,357, U.S. patent 6,920,822, and U.S. patent 7,373,878, the contents of which are incorporated herein by reference in their entirety.

One non-contact printing process is known as "direct-to-can" printing, in which a print head applies ink directly to a container. An example of such a technique is generally described in U.S. patent 9,327,493, the contents of which are incorporated herein by reference in their entirety. Some direct to can printing systems include an inkjet printing unit. The ink jet printing process is difficult to perform at high speed while maintaining undistorted print quality. This is because increasing the resolution of the decoration formed using prior art direct to can printing units generally reduces the metal container decoration rate. For example, some prior art direct to can printing units can decorate approximately 200 metal containers per minute at 180dpi image resolution. However, decorations with resolution of only 180dpi are not considered high definition decorations, nor are high quality decorations sought by consumers and advertisers. Other known direct-to-can printing units can decorate approximately 90 metal containers per minute at a resolution of 700 dpi. Such a rate is too slow for beverage container production lines where the on-line production equipment (including decorators) must typically run at a speed of 500-3000 metal containers per minute. More preferably, the decorator may need to be operated at a production speed that decorates at least one thousand cylindrical metal containers per minute, and even more preferably at a production speed that decorates several thousand cylindrical metal containers per minute.

Due to limitations associated with existing methods and apparatus for decorating metal containers, there is a need for an apparatus and method for decorating metal containers at high speeds in a high speed beverage container production system without sacrificing production efficiency or image quality.

Disclosure of Invention

The present invention provides various apparatuses and methods for decorating metal containers in an economically efficient, fast, and reliable manner. One aspect of the present invention is an apparatus and method for producing an image on an intermediate substrate (e.g., a transfer blanket) using a digital printing unit. The digital printing unit uses a decorative material to create the image. In one embodiment, the decoration material is one of ink and toner. The transfer blanket then transfers the image to an exterior surface portion of the metal container, an end cap, a tamper-proof (ROPP) cap, or a crown cap of the metal container.

In one embodiment, the digital printing unit comprises an inkjet printer or inkjet printhead that forms an image on a transfer blanket. In this embodiment, the decorative material includes ink. In one embodiment, the ink jet printer transfers at least one color or type of ink to a transfer blanket. In another embodiment, one or more inkjet printers may transfer more than one color or type of ink to the transfer blanket.

In one embodiment, the apparatus can change the viscosity of the inks delivered by the inkjet print head such that a first ink has a first viscosity and a second ink has a second viscosity. The apparatus may vary the viscosity by one or more of the following: the temperature of the ink is adjusted and the initiator in the ink is exposed to light of a specific wavelength. Alternatively, the light may be Ultraviolet (UV) light or Infrared (IR) light. In one embodiment, the apparatus may alter the viscosity of the ink prior to delivering the ink from the inkjet print head. Alternatively or additionally, the apparatus may alter the viscosity of the ink after it is discharged from the inkjet print head and before it is delivered to the transfer blanket. Therefore, the apparatus can adjust the temperature of the ink without heating the transfer blanket.

Alternatively or additionally, the apparatus may alter the viscosity of the ink after the ink jet print head delivers the ink to the transfer blanket. In one embodiment, the apparatus includes a temperature control device operable to heat or cool the transfer blanket to a predetermined temperature. Optionally, in another embodiment, the apparatus includes a light emitting device to expose the initiator in the ink on the transfer blanket to light of a particular wavelength, such as one or more of ultraviolet and infrared light. The apparatus can vary the viscosity of the ink on the transfer blanket in each of these ways.

In another embodiment, the one or more digital print units can include an electrophotographic digital print unit with an electrophotographic drum to form an image on the transfer blanket. The electrophotographic digital printing unit forms an image using toner material applied to an electrophotographic drum. The image formed by the toner is then transferred to a transfer blanket and then to a metal container. In one embodiment, the apparatus includes a plurality of electrophotographic digital printing units. Optionally, each electrophotographic digital printing unit forms a portion of an image. In one embodiment, the electrophotographic digital printing unit transfers a color or type of toner to a transfer blanket. In another embodiment, one or more electrophotographic digital printing units may transfer more than one color or type of toner to a transfer blanket.

In one embodiment, a first electrophotographic digital printing unit forms a first portion of an image using a first toner of a first color. The second electrophotographic digital printing unit forms a second portion of the image using a second toner of a second color. One or more additional electrophotographic digital printing units may similarly form portions of an image using one or more other colors of toner. In one embodiment, the toner material includes particles of one or more colors.

Alternatively, the toner may be a fine powder. In one embodiment, the toner may be charged. In another embodiment, the polarity of the toner is opposite to the charge polarity of the electrophotographic drum. In one embodiment, the toner may include a carrier. Optionally, the carrier comprises particles mixed with toner particles. In one embodiment, the carrier particles are larger than the toner particles. In another embodiment, the carrier particles are magnetic. Alternatively or additionally, the carrier particles may have an electrical charge.

Another aspect of the invention is a decorator that includes at least one digital print unit operable to form a decor on a transfer blanket. The trim includes a trim material that is subsequently transferred from the transfer blanket onto an exterior surface portion of the metal container. In one embodiment, the decoration material includes toner particles. In another embodiment, the decorative material comprises ink. Those skilled in the art will appreciate that the apparatus and methods described herein may be used with any type of surface or vessel and are not limited to cylindrical metal vessels. Thus, the apparatus and method of the present invention may be used to decorate a closure for a container, such as, but not limited to, an end cap adapted to interconnect with a neck of a container, a ROPP closure adapted to interconnect with a threaded neck of a container, or a crown cap adapted to interconnect with a neck of a container.

Another aspect of the present invention is to integrate the benefits of digital printing into high speed metal container decorating systems. Another aspect of the present invention is a high speed decorator that eliminates the problems and downtime associated with replacing and registering printing plates and is capable of efficiently decorating small batches of decorated metal containers or multiple metal containers, wherein each metal container is decorated with unique decorative content. Another aspect of the present invention is a method and apparatus for providing precise, high definition and variable decoration of metal containers while minimizing or eliminating equipment changeover and downtime on a high speed metal container production line. The decorator may be used to transfer a decoration to one or more of a metal container, an end closure for a metal container, a ROPP closure, and a crown cap. More specifically, in one embodiment, the decorator includes a digital printing unit that forms a decoration including a decor material on a transfer blanket. The transfer blanket then transfers the decoration to one of a metal container, a ROPP closure, and a crown cap. In one embodiment, the transfer blanket is a continuous loop or band of material. The decoration may be formed of at least one of ink and toner. In one embodiment, the digital printing unit includes an inkjet print head that uses ink to form the decoration. In another embodiment, the digital printing unit is an electrophotographic system that uses toner to form decorations.

Another aspect of the invention is a decorator configured to deliver a first ink to a transfer blanket and subsequently transfer a second ink to the transfer blanket while the first ink is in a wet or uncured state. In this manner, the decorator is operable to form a decoration on a transfer blanket that includes the first and second inks. The decorator may then transfer the decoration from the transfer blanket to the outer surface of the metal container. Alternatively, the decorator may deliver 2 to 10 inks to the transfer blanket to form a decoration while one or more inks remain uncured. After forming the decoration with the two or more inks, the two or more inks in the decoration may be cured using the curing unit. In one embodiment, the decorator may transfer 2 to 10 inks to the transfer blanket and then cure the first of the 2 to 8 inks. Optionally, one or more inks on the transfer blanket may be cured, or at least partially cured.

The decorator may include a first digital print unit that delivers a first ink. The second digital printing unit may deliver a second ink. Optionally, the first and second digital printing units are arranged such that the first digital printing unit delivers a first ink and then the second digital printing unit delivers a second ink.

In one embodiment, the first and second digital printing units comprise inkjet print heads. The first ink jet print head is configured to deliver a first ink to the transfer blanket. The second ink jet print head is configured to deliver a second ink to the transfer blanket prior to curing the first ink. Optionally, the first and second inks have the same color.

The decorator can adjust the viscosity of the first and second inks. For example, in one embodiment, the decorator adjusts a first ink to a first viscosity. The decorator adjusts the second ink to a second, different viscosity. In this manner, the first ink may have a first viscosity when delivered by the first digital printing unit, and the second ink may have a second viscosity when delivered by the second digital printing unit.

In one embodiment, varying or adjusting the viscosity of the first and second inks varies the size of the dots or drops of the first and second inks so that the first and second inks can be delivered to a location on the transfer blanket adjacent to one another to form a decoration while the first and second inks are in a wet or uncured state. Alternatively or additionally, changing the viscosity of the first ink prevents the dots or drops of the first ink from accidentally or accidentally moving on the transfer blanket, so that the second ink can be delivered to the transfer blanket before the first ink cures.

In one embodiment, the decorator is configured to change the temperature of the first and second inks to adjust the viscosity of the inks. The digital printing unit may include a temperature control device for varying the temperature of the ink. Alternatively, the decorator control system may send a signal to a temperature control device associated with the digital printing unit to change the temperature of the ink supplied to the digital printing unit. The control system may send a first signal to a first temperature control device to heat (or cool) a first ink to a first temperature and a second signal to a second temperature control device to cool (or heat) a second ink to a second temperature. In this way, the viscosity of the first and second inks can be adjusted.

Alternatively or additionally, the decorator may activate one or more initiators in the ink to change the viscosity of the ink. In one embodiment, the initiator is a photoinitiator. More specifically, in one embodiment, the initiator is activated by exposing the initiator to light of a predetermined wavelength. Optionally, the initiator is activated by ultraviolet light of a predetermined wavelength. The decorator may include at least one light emitter configured to emit light at a predetermined wavelength to activate the initiator in the ink. Thus, the decorator may change the viscosity of the ink. In one embodiment, the light may alter the viscosity of the ink prior to delivery of the ink from the inkjet print head. Alternatively, in another embodiment, the light may change the viscosity of the ink after the ink is delivered to the transfer blanket.

In one embodiment, the decorator includes a temperature control device configured to heat or cool the transfer blanket to a predetermined temperature. In this way, the size of the ink droplets on the transfer blanket can be changed. Alternatively or additionally, the humidity of the ink on the transfer blanket may be changed.

Another aspect of the invention is an apparatus for applying a decoration to an exterior surface of a metal container, the apparatus comprising: (1) a first transfer blanket section; (2) a digital printing unit in a predetermined alignment with respect to the first transfer blanket section, the digital printing unit operable to convey the trim material to the first transfer blanket section to form a trim on the first transfer blanket section; and (3) a feeding unit for moving the metal container into contact with the first transfer blanket section to transfer the decoration from the first transfer blanket section onto the outer surface of the metal container. In one embodiment, the first transfer blanket section may be spaced apart from the second transfer blanket section by a first distance adjacent the digital printing unit. Alternatively or additionally, in another embodiment, the first transfer blanket section may be spaced a second distance from the second transfer blanket section adjacent the feed unit. In one embodiment, the first distance is less than the second distance. In another embodiment, the first transfer blanket section is adjacent to the second transfer blanket section. More specifically, the first transfer blanket section may be disposed sequentially with the second transfer blanket, without a third transfer blanket section between the first and second transfer blanket sections.

Alternatively or additionally, the first and second transfer blanket sections may be configured to move at a first speed adjacent the digital print unit. Alternatively, the first and second transfer blanket sections may be configured to move at a second speed adjacent the feed unit. In one embodiment, the first speed is slower than the second speed.

In one embodiment, the first and second transfer blanket sections are part of a continuous loop of material. Thus, the first and second transfer blanket sections may define portions of a single transfer blanket. Alternatively, in another embodiment, the first and second transfer blanket sections may be separate blanket sections.

The decoration material may be at least one of ink and toner material. In one embodiment, the digital printing unit is an electrophotographic system. The electrophotographic system may include one or more of a conductor, a charging element, an exposure element, and a developing unit. The developing unit may be configured to supply a decorating material containing a toner material.

Alternatively or additionally, in one embodiment, the apparatus comprises an inkjet print head. The ink jet print head can be configured to transfer an ink containing decor material to one or more of the first transfer blanket section and the second transfer blanket section. Optionally, the apparatus may include a thermal system configured to adjust the viscosity of the ink. Alternatively or additionally, in one embodiment, the apparatus may include an ultraviolet system configured to adjust the viscosity of the ink.

The apparatus may include a curing unit. In one embodiment, the curing unit may be located downstream of the digital printing unit. Alternatively, the curing unit may be located upstream of the feeding unit. The curing unit may be configured to at least partially cure the trim material delivered to the first transfer felt section. In one embodiment, the curing unit may at least partially cure the trim material on the first transfer felt section before the trim material is transferred to the metal container.

Alternatively or additionally, the apparatus may include a temperature control device operable to adjust the temperature of one or more of the first and second transfer blanket sections. Optionally, the temperature may be selected to change the viscosity of the trim material. In one embodiment, the temperature control device can be configured to contact the first and second transfer felt sections. In another embodiment, the temperature control device is operable to adjust the temperature of one or more of the first and second transfer blanket sections without contacting the transfer blanket sections.

The apparatus may include a plurality of digital printing units, each digital printing unit operable to deliver one or more of a different color trim material and a different trim onto the first and second transfer blanket sections. Optionally, in one embodiment, the apparatus further comprises a second feeding unit. The second feeding unit may be configured to move the second metal container into contact with the second transfer blanket section to transfer the second decoration from the second transfer blanket section onto the outer surface of the second metal container. In one embodiment, the feeding unit is located upstream of the second feeding unit. Alternatively, the feeding unit may be aligned with the first image transfer position. Alternatively or additionally, the second feeding unit may be aligned with a second image transfer position.

Another aspect of the present invention provides a method of forming a decoration on an outer surface portion of a cylindrical container. The method generally includes, but is not limited to, one or more of the following steps: (1) transferring the decor material from the digital printing unit onto a first transfer felt section of the decorator such that the decor material forms a decoration on the first transfer felt section, the decor material including at least one of an ink and a toner material; (2) providing a cylindrical container; (3) placing the cylindrical container in a feed unit of a decorator; (4) changing the distance between the first transfer blanket section and the second transfer blanket section as the first and second transfer blanket sections move from the digital printing unit to the feed unit; and (5) moving an outer surface portion of the cylindrical container into contact with the first transfer blanket section. In this manner, the decoration may be transferred from the first transfer blanket section to the outer surface portion of the cylindrical container. In one embodiment, the first transfer blanket section may be configured to be spaced a first distance from the second transfer blanket section proximate the digital print unit. Alternatively, in another embodiment, the first transfer blanket section may be configured to be spaced a second distance from the second transfer blanket section adjacent the feed unit. In one embodiment, the second distance is greater than the first distance. In another embodiment, the first transfer blanket section is adjacent to the second transfer blanket section. More specifically, in one embodiment, the first and second transfer blanket sections may be arranged in series in the decorator.

Alternatively or additionally, in another embodiment, the first and second transfer blanket sections may be configured to move at variable speeds. In one embodiment, the first and second transfer blanket sections are movable at a first speed adjacent the digital print unit. Alternatively, in another embodiment, the first and second transfer blanket sections may be configured to move at a second speed adjacent the feed unit. In one embodiment, the second speed may be greater than the first speed. Thus, in another embodiment, the method optionally includes accelerating the first transfer felt section to a second speed.

In one embodiment, the first and second transfer blanket sections are part of a continuous loop of material. Thus, the first and second transfer blanket sections may define portions of a single transfer blanket. Alternatively, in another embodiment, the first and second transfer blanket sections may be separate blanket sections. Alternatively, the decorator may include a plurality of individual felt sections, and the first and second transfer felt sections include two of the plurality of individual felt sections.

The method may optionally include transferring further trim material from the digital printing unit to the second transfer blanket section to form a second trim on the second transfer blanket section. Additionally, the method may include providing a second cylindrical container. The second cylindrical container may optionally be placed in a second feed unit of the decorator. Optionally, an outer surface portion of the second cylindrical container is movable into contact with the second transfer felt section. In one embodiment, the second feeding unit may be located downstream of the feeding unit. In this way, the second decoration may be transferred to the outer surface portion of the second cylindrical container.

In one embodiment, transferring the trim material from the digital printing unit further comprises ejecting ink from an inkjet print head to the first transfer blanket segment. Alternatively or additionally, transferring the trim material from the digital printing unit may include transferring a toner material from an electrophotographic system to the first transfer felt section. The electrophotographic system may include a conductor. In one embodiment, the method includes charging the conductor. The method may also include exposing selected portions of the conductor to light to form a latent decoration. Optionally, the decorative material may be transferred to the latent decor. In this embodiment, the decorative material is a toner material. The method may also include transferring the trim material from the conductor to the first transfer felt section.

In another embodiment, the method may include at least partially curing the decoration. In one embodiment, the decoration may be cured while on the first transfer blanket section. Curing may be performed using a curing unit of the decorator. In one embodiment, the curing unit may be located downstream of the digital printing unit, but upstream of the feeding unit.

Optionally, the method may further comprise heating the first transfer felt section to a predetermined temperature. In another embodiment, the method can include cooling the first transfer felt section to a predetermined temperature. Alternatively or additionally, the method may include adjusting the viscosity of the trim material supplied to the digital printing unit. In another embodiment, the method can include varying the viscosity of the trim material on the first and second transfer blanket sections. In another embodiment, the decorator may adjust the viscosity of the trim material during conveyance of the trim material to the first and second transfer blanket sections.

One aspect of the present invention is a method of forming a decoration on an outer surface of a cylindrical container. The method includes but is not limited to: (1) charging a conductor of an electrophotographic system; (2) irradiating a surface of the conductor with light to form an electrostatic latent image thereon; (3) developing the electrostatic latent image with toner to form a toner image on the surface of the conductor; (4) transferring the toner image to a transfer blanket; and (5) transferring the toner image from the transfer blanket onto the outer surface of the cylindrical container. Optionally, the method further comprises curing the toner image using a curing device. In one embodiment, the toner image is at least partially cured or spot cured while on the transfer blanket. In another embodiment, the toner image is cured after being transferred onto the outer surface of the cylindrical container. In one embodiment, the curing device cures the toner image using heat.

One aspect of the present invention provides an apparatus for decorating a metal workpiece. The apparatus generally includes, but is not limited to: (1) transfer printing felt; (2) a digital printing unit in a predetermined alignment with respect to the transfer blanket, the digital printing unit operable to apply or deliver the trim material onto the transfer blanket; and (3) a feeding unit for moving the metal workpiece into contact with the transfer blanket to transfer at least some of the finishing material from the transfer blanket onto the metal workpiece. In this way, the apparatus forms a decoration on an outer surface portion of the metal workpiece. Optionally, the metal work piece comprises one of a metal container, an end closure for a metal container, a ROPP closure and a crown cap.

In one embodiment, the feeding unit includes at least a first feeding unit and a second feeding unit. The first feeding unit is disposed at a first image transfer position with respect to the transfer blanket. The second feeding unit is disposed at a second image transfer position with respect to the transfer blanket. In this way, the alternating decoration formed on the transfer blanket by the digital printing unit is transferred onto the metal workpiece supported by the first and second feeding units. In one embodiment, a first decoration on a transfer blanket is transferred to a first metal workpiece supported by a first feed unit. The second decoration on the transfer blanket is transferred to a second metal workpiece supported by a second feed unit. The second decoration is on the transfer blanket continuously with the first decoration.

The decoration may include any indicia, such as, but not limited to, a brand name, a logo, product information, or a design. The decoration may include, but is not limited to, one or more of symbols, images, letters, and numbers. In one embodiment, the decoration material is one of a toner material and an ink. In one embodiment, the toner material includes a fine powder.

In one embodiment, the digital printing unit comprises an inkjet print head. In another embodiment, the digital printing unit is operable to eject multiple colors of ink onto the transfer blanket. Alternatively, the digital printing unit may be operable to eject a single color of ink onto the transfer blanket. Optionally, the decorator is configured to alter the viscosity of the ink. In one embodiment, the decorator includes a temperature control device for heating or cooling the ink to a predetermined temperature. The decorator may further include a temperature control device for varying the temperature of the transfer blanket. In another embodiment, the ink supplied to the ink jet print head includes at least a first initiator that is activatable by light of a predetermined wavelength. The first initiator, when activated, increases the viscosity of the ink. The ink may include a second initiator that is activatable by light of a second wavelength. When the second initiator is activated, the viscosity of the ink decreases. Optionally, the decorator includes a light emitter configured to expose the ink to a predetermined wavelength required to activate the first initiator. Additionally, the decorator can include a second light emitter for exposing the ink to a second wavelength required to activate a second initiator.

In another embodiment, the digital printing unit comprises an electrophotographic system. The electrophotographic system includes an electrophotographic drum or conductor. The electrophotographic system is operable to transfer toner material to a transfer blanket. More specifically, in one embodiment, the toner material is attracted to a predetermined portion of the electrophotographic drum to form the decoration. The toner material is then transferred from the electrophotographic drum to a transfer blanket. In one embodiment, the electrophotographic system includes an electrophotographic drum, a charging element, an exposure element, and a developing unit with a supply of toner material. The toner material may be one or more colors. In one embodiment, the toner material includes at least one of a carrier and a colorant.

In one embodiment, a single digital printing unit forms the complete decoration on the transfer blanket. In another embodiment, the digital printing unit comprises 2 to 10 digital printing units. Optionally, each of the 2 to 10 digital printing units forms part of a decoration on the transfer blanket.

In one embodiment, the transfer felt comprises a single continuous sheet or loop of material, such as a strip of material. In another embodiment, the transfer blanket comprises a plurality of individual transfer blanket sections. In one embodiment, each transfer blanket segment is interconnected to a blanket wheel. Alternatively, each transfer blanket segment may change speed after the digital printing unit applies the trim material to the transfer blanket. In this way, the individual transfer blanket sections can be matched to the speed of the outer surface of the metal workpiece in the feed unit. In another embodiment, each transfer blanket segment has a first pitch adjacent the digital print unit and a second, larger pitch adjacent the feed unit.

In one embodiment, each transfer blanket section is located at a distal end of a blanket support extending from the blanket wheel. The felt supports are configured to change the position of their respective transfer felt segments relative to the felt wheel. In one embodiment, the distance between the blanket wheel and the transfer blanket section can be varied by moving a mating blanket support. In another embodiment, the felt support may move the mating transfer felt segment radially relative to the felt wheel. Alternatively, the felt support may pivot relative to the felt wheel. In one embodiment, the felt support includes a first section pivotally connected to a second section. In another embodiment, the felt support has a variable length. Alternatively or additionally, the felt wheel may include a recess or aperture to receive at least a portion of the felt support. Thus, the felt support may be retracted into or extended from the felt wheel.

In one embodiment, the apparatus includes at least one tensioning device for adjusting the tension of the transfer blanket. The tensioning device can solve the problem of abrasion or stretching of the transfer printing felt by increasing the tension, thereby improving the performance of the equipment. Optionally, the tension of the transfer blanket is selected to counteract a force received from the metal workpiece during transfer of the trim material thereto. In one embodiment, the tensioning device is adjustably arranged relative to the inner surface of the transfer blanket. Alternatively, the tensioner is placed near an image transfer position where the decorative material on the outer surface of the transfer blanket is transferred to the metal workpiece. In one embodiment, the tensioning device may be configured with an actuator. The actuator may change the position of the tensioner in response to signals received from the control system.

Optionally, in another embodiment, the apparatus may include one or more of a control system, a curing unit, and a cleaning system. The cleaning system is operable to remove residual trim material from the transfer blanket after the metal workpiece is contacted with the transfer blanket to receive the trim formed by the digital printing unit.

The control system is in communication with at least the digital printing unit and the feeding unit. Additionally, the control system may send signals to the digital printing unit to generate the decoration. In one embodiment, the control system may send signals to the digital printing unit to create a plurality of unique decorations. In response to receipt of the signal, the digital printing unit transfers the trim material to the transfer blanket to form a trim on the transfer blanket. The decoration material may include one or more of toner and ink. Then, the transfer blanket transfers the finishing material to the outer surface of the metal workpiece. In this manner, the apparatus can decorate a plurality of metal workpieces at very high rates of speed using unique decorations.

Alternatively, the control system may send a signal to the digital printing unit to change the viscosity of the ink to be delivered from the digital printing unit. The control system can also send a signal to a temperature control device to change the temperature of the transfer blanket. In this way, the temperature control device can heat or cool the transfer blanket to a predetermined temperature. In one embodiment, the control system may change the position of the felt support, such as by pivoting the felt support relative to the felt wheel. Alternatively or additionally, the control system may send a signal to an actuator operating in coordination with the felt support. The signal may cause the actuator to move the felt support in a particular direction. The control system may also move the felt support such that the distance between the transfer felt segment and the felt wheel changes. In one embodiment, the control system may cause the felt support to change its length. In another embodiment, the control system may send a signal to retract or extend the felt support into or out of the felt wheel.

In one embodiment, the curing unit may at least partially cure or "spot cure" the trim material. In another embodiment, the curing unit at least partially cures the trim material on the transfer blanket prior to transferring the trim to the metal work piece. Optionally, the apparatus may comprise a plurality of curing units. In one embodiment, each digital printing unit has an associated curing unit. In another embodiment, the apparatus comprises a single curing unit for curing or at least partially curing the decoration after the decoration is formed by the one or more digital printing units. In this manner, the curing unit may at least partially cure the decoration while the decoration is on the transfer blanket. Optionally, in another embodiment, the curing unit cures the decoration after the decoration is transferred from the transfer blanket onto the outer surface portion of the metal workpiece. In one embodiment, the curing unit is operable to cure the ink. In another embodiment, the curing unit is operable to cure one or more uv-curable inks with uv light, cure water-based inks with thermal energy, and cure mineral oil-based inks with thermal energy. In one embodiment, the curing unit is operable to cure the toner material containing particles.

Another aspect of the invention provides a method of decorating an exterior surface portion of a container. The method includes but is not limited to: (1) providing a container; and (2) decorating the container with a decorator comprising: (a) a digital printing unit; and (b) a transfer blanket in a predetermined alignment with respect to the digital printing unit such that the transfer blanket receives the trim material from the digital printing unit. Thus, when the exterior surface portion of the container is in contact with the transfer blanket, at least some of the trim material from the transfer blanket is transferred to the container to form a trim on the exterior surface portion of the container. In one embodiment, the exterior surface portion of the container comprises one of a body portion of the container, a closed end of the container, an end cap of the container, a ROPP closure, and a crown cap. Alternatively, the decoration material may be one or more of toner and ink.

In one embodiment, the digital printing unit includes one of an inkjet print head and an electrophotographic drum or a photographic plate. In another embodiment, the digital printing unit is operable to eject multiple colors of ink onto the transfer blanket. Alternatively, the digital printing unit is operable to eject a single color of ink onto the transfer blanket. In another embodiment, the digital printing unit is operable to transfer toner to a transfer blanket. In one embodiment, the toner transferred by the digital printing unit includes a plurality of colors.

In one embodiment, a single digital printing unit forms the complete decoration on the transfer blanket. In another embodiment, the digital printing unit comprises 2 to 10 digital printing units. In one embodiment, each of the 2 to 10 digital printing units may form a portion of the decoration on the transfer blanket. In another embodiment, each of the 2 to 10 digital print units may deliver a different color ink or a different image to the transfer blanket. In one embodiment, the 2 to 10 digital printing units comprise one or more of an inkjet print head and an electrophotographic drum.

In another embodiment, the transfer blanket comprises a plurality of individual transfer blanket sections. In this embodiment, the method may further comprise changing the position of the transfer felt segment relative to the felt wheel. In one embodiment, the method includes varying the distance between the transfer blanket section and the blanket wheel. In another embodiment, the method may include pivoting the felt support and associated transfer felt section relative to the felt wheel. Optionally, the method may further comprise varying the spacing or distance between adjacent transfer blanket sections. In one embodiment, adjacent transfer blanket segments have a first pitch adjacent the digital print unit and a second pitch at the image transfer location where the container contacts the transfer blanket. Alternatively, in another embodiment, the transfer felt comprises a single continuous sheet or loop of material.

In one embodiment, the transfer blanket comprises one of a photopolymer material or a compound that at least partially comprises polymethylene saturated chains. In another embodiment, the polymethylene saturated chain of the transfer blanket comprises Ethylene Propylene Diene Monomer (EPDM) rubber as known to those skilled in the art. In another embodiment, the transfer felt includes a face portion comprising a rubber material known as nitrile rubber.

Alternatively, the method may include changing the viscosity of an ink associated with the digital printing unit. In one embodiment, the method includes activating an initiator in the ink to change the viscosity of the ink. In another embodiment, the method includes heating or cooling the ink to change the viscosity of the ink. Alternatively or additionally, the method may further comprise adjusting the temperature of the transfer blanket. The temperature of the transfer blanket may be adjusted before or after the trim material is delivered to the transfer blanket by the digital printing unit.

In one embodiment of the invention, the decorator optionally includes one or more of a feed unit, a control system, a curing unit, and a cleaning system. The feed unit is operable to move the container into a predetermined alignment with respect to the transfer blanket. In one embodiment, the feed unit receives a container from an upstream device. The upstream apparatus may comprise a surface treatment unit.

Alternatively, the decorator may include a first feeding unit and a second feeding unit. In one embodiment, the method may further comprise: (a) forming a first decoration, a second decoration and a third decoration on the transfer printing felt by using a digital printing unit; (b) the first feeding unit moves the first container into contact with the transfer blanket so that the first decoration is transferred onto the first container; (c) a second feeding unit moves the second container into contact with the transfer blanket so that the second decoration is transferred onto the second container; and (b) the third feeding unit moves the third container into contact with the transfer blanket so that the third decoration is transferred onto the third container. In one embodiment, the first, second and third decorations are continuously formed on the transfer blanket. In this way, the first and third decorations can be transferred onto the first and third containers while the first and third containers are supported by the first feeding unit. Similarly, the second decoration may be transferred onto the second container while the second container is supported by the second feeding unit.

The cleaning system is in a predetermined orientation relative to the transfer blanket. In one embodiment, the cleaning system is operable to remove residual trim material from the transfer blanket after the container is contacted with the transfer blanket to receive the trim formed by the digital printing unit.

The control system is in communication with one or more of the digital printing unit and the feed unit. Additionally, the control system may send signals to the digital printing unit to generate the decoration. In one embodiment, the control system may send signals to the digital printing unit to generate a plurality of unique decorations to be formed on the transfer blanket by the digital printing unit. In one embodiment, the decoration formed by the digital printing unit includes at least one of ink and toner. In this manner, the decorator can decorate a plurality of containers with unique decorations.

In one embodiment, the curing unit may at least partially cure the decoration on the transfer blanket before the decoration is transferred to the container. Alternatively, in another embodiment, the curing unit cures the decoration on the container. Optionally, the decorator may include a plurality of curing units. Optionally, the decorator may include a first digital print unit and a second digital print unit. The first digital printing unit may transfer the first trim material to one or more of the first, second, and third trims. The second digital printing unit may transfer the second trim material to one or more of the first, second, and third trims. In one embodiment, each of the first and second digital print units has an associated curing unit. In another embodiment, the decorator includes a single curing unit for curing or at least partially curing the decor after it is formed by the one or more digital printing units. More specifically, in one embodiment, the curing unit is configured to at least partially cure the first, second, and third decors after the first and second digital printing units transfer their respective first and second decor materials to the transfer blanket. In one embodiment, the curing device is configured to at least partially cure the first, second, and third decors while the trim material of the first and second digital printing units is on the transfer blanket. Alternatively, in another embodiment, the curing device is configured to at least partially cure the first, second, and third decorations after the trim material is transferred from the transfer blanket onto the respective first, second, and third containers. In another embodiment, the curing unit is operable to cure one or more of toner, uv curable ink, water-based ink, and oil-based ink (e.g., mineral ink).

Another aspect of the invention is a container decorated by a decoration formed by an electrophotographic system on an intermediate substrate (e.g., a transfer blanket). Such containers include, but are not limited to: (1) a bottom portion; (2) a body portion extending upwardly from the bottom portion, the body portion including an outer surface portion; (3) an opening at an uppermost portion of the main body portion; and (4) a decoration on the outer surface portion, the decoration including a digital image formed by the toner transferred onto the transfer blanket by the electrophotographic system, wherein the toner on the transfer blanket is transferred onto the outer surface portion of the container while the outer surface portion of the container is rotated in contact with the transfer blanket. In one embodiment, the toner is solidified after being transferred onto the outer surface portion of the container.

In one embodiment, the decoration has a resolution of at least about 1600 x 1600 dots/inch. In another embodiment, the decoration comprises up to five colors of toner. In another embodiment, the container comprises a metal container. In another embodiment, the container is one of a beverage container, an aerosol container and a food container. In another embodiment, the container is formed from one or more of aluminum, steel, tin, plastic, paper, and glass.

Another aspect of the invention is a method of forming a decoration on an exterior surface portion of a first cylindrical container. The method includes, but is not limited to, one or more of the following steps: (1) transferring the decor material from the digital printing unit onto a transfer blanket of a decorator, the decor material defining a decoration; (2) providing a first cylindrical container; (3) placing the first cylindrical container in a feed unit of a decorator; and (4) moving an outer surface portion of the first cylindrical container into contact with the transfer blanket. In this manner, the trim material defining the trim is transferred from the transfer blanket onto the exterior surface portion of the first cylindrical container. In one embodiment, the decorating material includes at least one of an ink and a toner material.

In one embodiment, the transfer felt comprises a plurality of individual felt segments. Optionally, the individual felt sections are operable to match the rotational speed of a first cylindrical container located in the feed unit. In another embodiment, the transfer blanket is a continuous loop of material.

In one embodiment, the decorator further includes one or more of a cleaning system and a curing unit to at least partially cure the trim material. The cleaning system is operable to remove residual trim material from the transfer blanket. Optionally, the curing unit is operable to at least partially cure one or more of a toner material, a uv curable ink, a water-based ink, and a mineral oil-based ink.

In one embodiment, the curing unit is configured to at least partially cure the trim material on the transfer blanket. Optionally, the curing unit may cure the trim material transferred from the two or more digital printing units to the transfer blanket. More specifically, in one embodiment, the curing unit may cure the upholstery material from two or more digital printing units on the transfer blanket. Thus, in one embodiment, the curing unit is located downstream of all digital printing units. In this manner, the wetted or uncured trim material transferred to the transfer blanket by the one or more digital printing units may be at least partially cured by a single curing unit. In one embodiment, the second trim material is delivered to the transfer blanket before the first trim material on the transfer blanket is cured. In another embodiment, the curing unit is configured to at least partially cure the trim material after the trim material is transferred onto the outer surface portion of the first cylindrical container.

In one embodiment, the feed unit comprises a plurality of spindles operable to rotate. In one embodiment, the mandrel rotates such that the first cylindrical container rotates at a rate substantially equal to the rate of transfer felt.

Optionally, the feeding unit of the decorator includes at least a first feeding unit and a second feeding unit. In one embodiment, the digital printing unit is configured to continuously form the first and second decorations of trim material on the transfer blanket. The first feed unit is aligned relative to the transfer blanket to transfer the first decoration to the first cylindrical container. The second feed unit is aligned relative to the transfer blanket to transfer the second decoration to the second cylindrical container. The first feeding unit may be arranged to move the cylindrical container into contact with the transfer blanket at the first image transfer position. The second feeding unit is arranged to move the cylindrical container into contact with the transfer blanket at the second image transfer position.

In another embodiment, the decorator includes a tensioner in operable contact with the transfer blanket. Optionally, the method may further comprise adjusting the tension of the transfer blanket by a tensioning device. For example, the control system may send a signal to an actuator associated with the tensioner. The signal may cause the actuator to move the tensioner in a particular direction.

In one embodiment, the digital printing unit includes an electrophotographic system. The method may further comprise: charging a conductor of an electrophotographic system; exposing selected portions of the conductor to light to form a latent decoration; transferring a decorative material onto the latent decor, wherein the decorative material is a toner material; and transferring the finishing material from the conductor to the transfer blanket. In this manner, the electrophotographic system can form a decoration on the transfer blanket.

In another embodiment, the control system is in communication with a decorator. The method may further comprise: the decoration is generated by the control system. Optionally, the method may comprise: a signal is sent by the control system to the digital printing unit. The signal may cause the digital printing unit to transfer the trim material to the transfer blanket. In another embodiment, the method may comprise: the control system sends a signal to the temperature control device. The signal may cause the temperature control device to perform one or more of the following operations: (i) changing the temperature of the ink; and (ii) changing the temperature of the transfer blanket. In another embodiment, the method optionally comprises: a signal to change the viscosity of the ink is sent by the control system. In one embodiment, the signal causes the optical transmitter to generate light at a predetermined wavelength. The light activates an initiator in the ink. The initiator, when activated, increases or decreases the viscosity of the ink. The light emitters may be arranged to bring light into contact with the ink before the ink is transferred to the transfer blanket. In another embodiment, the light emitters are arranged to generate light that contacts ink on the transfer blanket. In another embodiment, the light emitters are arranged to generate light that impinges the ink as it is ejected from the inkjet print head and before the ink contacts the transfer blanket.

Another aspect of the present invention provides a decorator having two or more feed units. These feed units may be arranged to transfer the alternating decoration formed on the transfer blanket to a metal container supported by the feed units. In one embodiment, the first feed unit transfers every other decoration on the transfer blanket to the metal container. More specifically, the first feeding unit may transfer the first decoration and the third decoration of the continuous decoration on the transfer blanket onto the metal container supported by the first feeding unit. The second feeding unit may transfer the continuous second decoration and the fourth decoration of the decorations onto the metal container supported by the second feeding unit.

In another aspect, a decorator can include a transfer blanket having two or more blanket sections adjacently disposed side-by-side. Each felt section forms a loop. The felt sections may be decorated by one or more digital printing units. The felt section may then be moved through two or more support elements. Each support element can move the metal container into contact with the trim material on one of the felt sections. In one embodiment, a decorator includes two felt sections and two support elements. Each support element is associated with one of the two felt sections. In this way, the decorator can produce a metal container in two passes. In another embodiment, the decorator includes four support elements and four annular felt segments. Each support element is associated with one of the four felt sections.

Another aspect provides a decorator having a felt wheel including a felt support extending therefrom. Each felt support member has an associated transfer felt section. In one embodiment, the felt support has a variable length. In this manner, the position of the transfer blanket section disposed on the blanket support may be varied as the blanket wheel rotates. In the first position, the transfer blanket section may be a first distance from the blanket wheel. In the second position, the transfer blanket section may be a second distance from the blanket wheel. In another embodiment, the felt support is pivotally interconnected with the felt wheel. In another embodiment, one or more of the felt supports includes a joint. Thus, as the blanket wheel rotates, the blanket support may bend or move the transfer blanket segment interconnected thereto.

Another aspect of the invention is a decorator having a curing device configured to cure trim material from at least two digital printing units. The decorator includes, but is not limited to: (1) a first digital printing unit configured to transfer a first upholstery material onto a transfer blanket of a decorator, the first upholstery material constituting at least a portion of a first decor; (2) a second digital printing unit configured to transfer a second finishing material onto the transfer blanket, the second finishing material constituting at least another portion of the first finishing; and (3) curing means for at least partially curing the first and second decorative materials. In one embodiment, the second digital printing unit transfers the second trim material to a location on the transfer blanket adjacent the first trim material before the first trim material is cured by the curing device. In one embodiment, the curing device is located downstream of the second digital printing unit. More specifically, in one embodiment, the curing device is located between the second digital printing unit and the image transfer location of the decorator.

In one embodiment, the curing device is configured to cure the first and second finishing materials on the transfer blanket. In another embodiment, the curing device is configured to cure the first and second trim materials on the outer surface of the cylindrical container.

Optionally, the first and second decorating materials are one of toner and ink. In one embodiment, the first digital printing unit is one of an inkjet print head and an electrophotographic system. In another embodiment, the second digital printing unit is one of an inkjet print head and an electrophotographic system.

In one embodiment, the first and second digital printing units comprise first and second inkjet print heads. The decorator is configured to change the viscosity of the first and second inks of the respective first and second inkjet print heads. In one embodiment, the decorator includes a temperature control device configured to heat or cool the transfer blanket to a predetermined temperature. In another embodiment, the decorator includes a temperature control device configured to vary the temperature of the first and second inks supplied to the first and second inkjet print heads.

Alternatively or additionally, the first and second inks may include an initiator that is activated by light of a predetermined wavelength. The first initiator, when activated, increases the viscosity of the ink. The second initiator, when activated, may reduce the viscosity of the ink. The decorator can include a light emitter associated with the first and second ink jet print heads. The first light emitter may generate light at one or more predetermined wavelengths to selectively activate at least one of the first and second initiators in the first ink. The second light emitter may be configured with a second ink jet print head to selectively activate the first and second initiators in the second ink.

One aspect of the present invention is an apparatus for decorating the exterior surface of a metal container. Such devices include, but are not limited to: (1) transferring a felt; (2) a digital printing unit in a predetermined registration state with respect to the transfer blanket, the digital printing unit operable to convey the trim material to the transfer blanket to form at least a portion of the first and second decorations on the transfer blanket; (3) a first feeding unit for moving the first metal container into contact with the transfer blanket to transfer the first decoration from the transfer blanket onto an outer surface of the first metal container; and (4) a second feeding unit for moving the second metal container into contact with the transfer blanket to transfer the second decoration from the transfer blanket onto an outer surface of the second metal container. The decorating material includes at least one of ink and toner material. In one embodiment, the transfer blanket is a continuous loop of material. Alternatively, the transfer felt comprises a plurality of individual felt segments. The first feeding unit may be aligned with a first image transfer position of the apparatus, and the second feeding unit may be aligned with a second image transfer position of the apparatus.

In one embodiment, the apparatus includes a plurality of digital printing units. Each digital printing unit is operable to deliver one or more of a different color trim material and a different trim to the transfer blanket.

Optionally, the apparatus comprises a curing unit downstream of the plurality of digital printing units. In one embodiment, the curing unit is configured to at least partially cure the trim material conveyed onto the transfer blanket by the plurality of digital printing units. The curing unit may be positioned between the digital printing unit and the first and second image transfer positions. In another embodiment, the curing unit is operable to cure the trim material on the outer surface of the metal container. For example, the curing unit may be positioned after one or more of the first and second image transfer positions.

In one embodiment, the apparatus includes a temperature control device operable to adjust a temperature of the transfer blanket. The temperature control device may heat or cool the transfer blanket to a predetermined temperature. Optionally, the viscosity of the finishing material is changed when the temperature control device adjusts the temperature of the transfer blanket.

In one embodiment, the digital printing unit is an electrophotographic system that includes a conductor, a charging element, an exposure element, and a developing unit that provides a finishing material that includes toner. In another embodiment, the digital printing unit is an inkjet print head and the decorating material is an ink. The apparatus may further include one or more of a thermal system and an ultraviolet system configured to adjust the viscosity of the ink.

Another aspect of the invention is a method of forming a decoration on an exterior surface portion of a cylindrical container. The method generally includes, but is not limited to, one or more of the following steps: (1) transferring the decorating material from the at least two digital printing units to a transfer blanket of the decorating machine so that the decorating material forms a decoration on the transfer blanket; (2) at least partially curing the decoration on the transfer blanket using a curing unit; (3) providing a cylindrical container; (4) placing the cylindrical container in a first feeding unit of a decorator; and (5) moving an outer surface portion of the cylindrical container into contact with the transfer blanket. In this way, the decoration is transferred from the transfer blanket onto the outer surface portion of the cylindrical container. The decorating material may include at least one of ink and toner material. Optionally, the transfer blanket comprises one of a plurality of individual blanket segments and a loop of continuous material.

The method may further include pivoting the transfer blanket section relative to a blanket wheel of the decorator. Alternatively or additionally, the method may include varying the distance between the transfer blanket section and the blanket wheel.

In one embodiment, the method comprises one or more of the following steps: (i) transferring further trim material from the at least two digital printing units to the transfer blanket to form a second trim on the transfer blanket; (ii) providing a second cylindrical container; (iii) placing the second cylindrical container in a second feed unit of the decorator; and (iv) moving an outer surface portion of the second cylindrical container into contact with the transfer blanket at a location downstream of the first feeding unit. In this way, the second decoration is transferred onto the outer surface portion of the second cylindrical container at a second image transfer position of the decorator, which is different from the first image transfer position associated with the first feeding unit.

The curing unit may be positioned downstream of the at least two digital printing units. Optionally, the curing unit is operable to cure one or more of a toner material, a uv curable ink, a water-based ink, and a mineral oil-based ink. In one embodiment, the curing unit is positioned upstream of one or more of the first and second image transfer positions.

In one embodiment, transferring the trim material from the at least two digital printing units further comprises one or more of the following steps: (a) charging a conductor of a first digital printing unit of the at least two digital printing units, the first digital printing unit being an electrophotographic system; (b) exposing selected portions of the conductor to light to form a latent decoration; (c) transferring a decorative material to the latent decor, the decorative material being an ink powder material; and (d) transferring the finishing material from the conductor to a transfer blanket.

In another embodiment, the method further comprises: (1) transferring the finishing material from the conductor to a transfer blanket; and (2) sending, by the control system, a signal to at least the two digital printing units, wherein the signal causes the at least two digital printing units to transfer the trim material to the transfer blanket.

The method may further include heating the transfer blanket to a predetermined temperature. Alternatively or additionally, the method may include adjusting a viscosity of a decorating material supplied to at least one of the at least two digital printing units, wherein the decorating material is an ink. In one embodiment, adjusting the viscosity of the ink includes one of heating or cooling the ink. In another embodiment, adjusting the viscosity of the ink includes activating an initiator in the ink. Activating the initiator may include exposing the initiator to light of a predetermined wavelength.

Another aspect of the present disclosure provides a decorator for decorating a metal container. The decorator generally includes, but is not limited to: (1) a felt wheel operable to rotate; (2) spokes extending generally radially from the wheel, each spoke having a distal end spaced from the wheel; (3) a transfer blanket section interconnected to the distal end of each spoke; (4) a digital printing unit configured to deliver a finishing material to the transfer felt segments as the blanket wheel rotates the spokes and passes the digital printing unit, the finishing material for forming a decoration on each transfer felt segment; and (5) a feeding unit for moving the metal container into contact with the transfer felt section to transfer the decoration onto the outer surface of the metal container. Optionally, at the distal end of each spoke, the distance between the felt wheel and the transfer felt section is adjustable.

In one embodiment, the length of each spoke is adjustable. In another embodiment, each spoke may be at least partially retracted into the felt wheel. Alternatively or additionally, the spokes may pivot relative to the felt wheel.

In another embodiment, each spoke includes a first section interconnected with the felt wheel and a second section including a distal end. The first segment is pivotably interconnected with the second segment.

In one embodiment, the distal ends of the spokes are movable relative to the felt wheel. Thus, a first transfer blanket segment interconnected to a first spoke and a second transfer blanket segment interconnected to a second spoke may be spaced apart a first distance adjacent the digital printing unit. As the blanket wheel rotates, the distal ends of the spokes move so that the first and second transfer blanket sections may be spaced apart a second distance adjacent the feed unit.

Although the containers are generally described herein as "metal containers," "beverage containers," "cans," and "containers," it should be understood that the present invention may be used to decorate containers of any size or shape, including but not limited to beverage cans, beverage bottles, food cans, and aerosol containers. The term "container" is therefore intended to cover any type of container for any product, and is not limited to beverage containers, which may be soft drink cans or beer cans, for example. The container may also be in any state of manufacture. Further, the container may be formed by a ironing process or a punching process. Thus, the present invention may be used to decorate "cups" that are subsequently formed into finished containers, "bottle blanks" that are subsequently formed into metal bottles, or "tubes" that are formed into aerosol container bodies. Furthermore, the present invention may be used to decorate any portion of a container. For example, in one embodiment of the invention, the decorator may be used to decorate an exterior surface portion of a container, including one or more of a closed end portion and an exterior surface portion of a body portion of the container. In another embodiment of the invention, the decorator may decorate an exterior surface portion of an end cap adapted to interconnect with a neck portion of a container. In another embodiment, the decorator of the present disclosure can decorate the outer surface of a ROPP closure adapted to interconnect with a threaded neck of a container. In another embodiment, the decorative material may be transferred onto an outer surface portion of a crown cap adapted for interconnection with a container neck.

The term "metal" as used herein refers to any metallic material that may be used to form a container, including, but not limited to, aluminum, steel, tin, and any combination thereof. However, it should be understood that the apparatus and method of the present invention may be used to decorate containers formed of any material, including paper, plastic, and glass. Further, while the method and apparatus of the present invention are generally described in connection with decorating metal containers having a generally cylindrical body, it should be understood that the method and apparatus of the present invention may be used to decorate any type of substrate, including continuous metal, plastic, or paper webs or sheets.

The phrases "at least one," "one or more," and/or "as used herein are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions "at least one of A, B and C", "at least one of A, B or C", "one or more of A, B and C", "one or more of A, B or C", and "A, B and/or C" means a only, B only, C only, a and B, a and C, B and C, or A, B and C.

Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth, used in the specification and claims are to be understood as being modified in all instances by the term "about" or "approximately". Accordingly, unless indicated otherwise, all numbers expressing quantities, dimensions, conditions, ratios, ranges, and so forth used in the specification and claims are to be increased or decreased by about 5% in order to achieve satisfactory results. Moreover, all ranges described herein can be reduced to any subrange or portion of the range, or to any value within the range, without departing from the invention.

The terms "a" and "an" as used herein refer to one or more entities. Thus, the terms "a", "an", "one or more" and "at least one" are used interchangeably herein.

The use of the terms "comprising," "including," or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Thus, the terms "comprising," "including," or "having" and variations thereof are used interchangeably herein.

It should be understood that the term "device" as used herein should be interpreted as broadly as possible in light of the interpretation provided in section 112(f) of 35u.s.c. Accordingly, the claims, when read in conjunction with the term "means" are intended to cover all of the structures, materials, or acts set forth herein, as well as all equivalents thereof. Rather, the structures, materials, or means, and equivalents thereof, are intended to include all such things as are within the summary, brief description of the drawings, detailed description, abstract, and claims themselves.

The summary of the invention is not intended to, and should not be taken as, representative of the full scope and scope of the invention. Moreover, references herein to "the invention" or aspects thereof should be understood to refer to particular embodiments of the invention, and not to limit all embodiments to the particular descriptions herein. It is to be understood that other embodiments can be realized by using one or more of the features described above or described in detail below, either individually or in combination. For example, it is contemplated that various features and devices illustrated and/or described with respect to one embodiment or figure may be combined with or substituted for those of the other embodiments or figures, whether or not such combination or substitution is explicitly illustrated or described in the present disclosure. The invention is described in varying degrees of detail in this summary of the invention and in the accompanying drawings and detailed description of the invention, and the inclusion or non-inclusion of particular elements or components in this summary of the invention is not intended to limit the scope of the invention. Additional features of the invention will become apparent upon reading the detailed description, particularly when read in conjunction with the appended drawings.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the general description given above and the detailed description given below, serve to explain the principles of these embodiments. In certain instances, details that are not necessary for an understanding of the present disclosure or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not limited to the particular embodiments illustrated herein. Additionally, it should be understood that the drawings are not necessarily drawn to scale.

FIG. 1 is a schematic flow diagram of a decorator showing one embodiment of the present invention and also showing a metal container, end closure and crown cap decorated by the decorator of the present invention;

FIG. 1A is a schematic flow diagram of a decorator that includes a felt support having a variable length such that the relative speed of the transfer felt segments can be varied as the felt support rotates;

FIG. 1B is a schematic flow diagram of a decorator in which a transfer blanket section is interconnected with a blanket support that is pivotable relative to a blanket wheel;

FIG. 1C is a schematic flow diagram of a decorator that includes two feed units aligned with a felt wheel having a transfer felt segment thereon;

FIG. 2A is a schematic view of a digital printing unit including an inkjet print head according to one embodiment of the present invention;

FIG. 2B is a schematic view of a digital printing unit including an electrophotographic system for forming a decoration that is transferred to a transfer blanket of a decorator in accordance with one embodiment of the present invention;

FIG. 3 is another schematic flow diagram of another embodiment of the decorator of the present disclosure, including a continuous transfer blanket;

FIG. 3A is a partial view of the decorator of FIG. 3 showing the inboard idler engaging the continuous transfer blanket in one use position;

FIG. 3B is another partial view of the decorator of FIG. 3 showing a rear idler engaging the continuous transfer blanket;

FIG. 3C is another partial view of the decorator of FIG. 3 showing the shoe tensioner 58 after movement relative to the continuous transfer blanket;

FIG. 3D is a partial view of a tensioning device having two rollers mated to a continuous transfer blanket;

FIG. 3E is a schematic flow diagram of the decorator of FIG. 3 equipped with two feed units;

FIG. 4 is another schematic flow diagram of another embodiment of the decorator of the present disclosure, including a feed unit having a plurality of spindles;

FIG. 5 is a cross-sectional view taken along line 5-5 in FIG. 4 of a transfer blanket of one embodiment of the present invention;

fig. 5A is a partial cross-sectional view of a decorator including two feed units according to another embodiment of the present invention; and

FIG. 6 is a block diagram of one embodiment of a control system of the present invention.

Similar components and/or features may have the same reference numerals. Components of the same type may be distinguished by letter plus reference numerals. If only reference numerals are used, the corresponding description applies to any one of the similar components having the same reference numerals.

To assist in understanding the invention, the following component tables and corresponding reference numerals in the drawings are provided:

reference character element

2 decorating machine

4 digital printing unit

5 temperature control device

6 transfer printing felt

6A transfer blanket section

6B continuous transfer printing felt

6C continuous transfer printing felt

7 decoration on felt

8 feeding unit

9 working position

10 conveyor belt

11 mandrel

12 control system

13 conveyer belt

14 cleaning system

15 distance between adjacent transfer blanket sections

16 curing unit

17 curing unit

18 felt wheel or felt roller

20 felt support

21 distance between the felt wheel and the felt section

22 Metal container

23 first decoration

24 outer surface of metal container

25 image transfer position

26 upstream plant

27 surface treatment unit

28 decorated metal container

29 pivot joint

30 decoration of metal container

31 second pivot joint

32 downstream equipment

33 third pivot joint

34 end cap

36 crown cap

37 first section of felt support

38 second section of felt support

39 third section of felt support

40 electrophotographic system

41 ink jet print head

42 conductor

43 ink

44 charging element

45 spray nozzle

46 exposure element

47 light emitter

48 developing unit

49 roller

50 transfer charging element

51 ink source

52 toner

53 orifice

54 inside idler

55 light

56 rear idler

58 shoe tensioner

60 rotating tensioner

60A double-roller rotary tensioning device

61 roller of a two-roller tensioning device

62 embossing roll

63 connecting rod

64 servo drive device

65 felt width

66 transfer blanket section

67 longitudinal edges of felt section

68 bus

70 CPU

72 input device

74 output device

76 storage device

78 computer readable storage medium reader

80 communication system

82 working memory

84 optional processing acceleration

86 database

88 network

90 database

92 operating system

94 other codes

Detailed Description

The present invention has significant advantages in many respects. Although the language used in the specification may have been limited to the specific examples disclosed, it is the applicants' intention to conform the specification and the appended claims to the scope and spirit of the invention. To facilitate an understanding of the invention by those skilled in the art to which the invention relates most, a preferred embodiment of the invention will be described herein with reference to the accompanying drawings which form a part hereof, and which show by way of illustration the best mode contemplated for carrying out the invention so far. The detailed description is of exemplary embodiments and is not intended to describe all of the various forms or modifications in which the present invention may be practiced. Thus, the embodiments described herein are exemplary and it will be apparent to those skilled in the art that modifications may be made in many ways within the spirit and scope of the invention.

Referring now to fig. 1, there is shown a schematic flow diagram of a decorator 2 of the present invention. Decorator 2 generally includes at least one digital print unit 4, a transfer blanket 6, a feed unit 8,

conveyor belts

10, 13, and a control system 12. In one embodiment, the transfer blanket 6 includes a plurality of transfer blanket sections 6A. Decorator 2 may optionally include one or more of a cleaning system 14 and curing or drying units 16, 17. Alternatively, decorator 2 may include at least one temperature control device 5.

The digital printing unit 4 is in a predetermined alignment with respect to the transfer blanket 6. The digital printing unit 4 forms a decoration 7 on the transfer blanket 6. In one embodiment, decorator 2 includes one to four

digital print units

4A, 4B, 4C, 4D. However, it should be understood that any number of digital print units 4 may be used in conjunction with decorator 2 of embodiments of the present invention. For example, in one embodiment, decorator 2 includes one to ten different digital print units 4.

In one embodiment, the digital printing unit 4 is in contact with the transfer blanket 6 to form indicia or decoration 7 on the transfer blanket 6. Alternatively, in another embodiment, the digital printing unit 4 is not in contact with the transfer blanket 6, but rather the indicia or decoration 7 is applied to the transfer blanket without contact. In one embodiment, digital printing unit 4 can form decorations with a resolution of at least 1600 x 1600 dots/inch. Therefore, the decoration 7 formed on the transfer blanket 6 is considered to be a high definition image.

In one embodiment, the digital printing unit 4 delivers ink to the transfer blanket 6 by spraying, jetting, or otherwise, to form the decoration 7 on the transfer blanket 6. In one embodiment, one or more digital printing units 4 comprise an inkjet printer or inkjet printhead 41 (e.g., as shown in fig. 2A). In another embodiment, the digital printing unit 4 forms the decoration 7 on the transfer blanket 6 by transferring toner to the transfer blanket. More specifically, in one embodiment, digital printing unit 4 includes an electrophotographic system 40 (shown generally in FIG. 2B) that transfers toner material 52 onto a transfer blanket. One of the digital printing units 4 may be an inkjet printer and another of the digital printing units 4 is an electrophotographic system 40. The order and relative position of the digital printing units 4 with respect to the blanket wheel 18 may be varied.

In one embodiment, each of the

digital printing units

4A, 4B, 4C, 4D delivers a single color or type of trim material onto the transfer blanket 6. In this way, the first digital printing unit 4A conveys the first decorating material to the transfer blanket 6. Similarly, the second digital printing unit 4B conveys the second finishing material to the transfer blanket 6, the third digital printing unit 4C conveys the third finishing material, and the fourth digital printing unit 4D conveys the fourth finishing material. The decorating material delivered by each digital printing unit is one of ink and toner. The decoration 7 formed on the transfer blanket 6 may include one or more of the first, second, third and fourth inks and/or toners. The upholstery material from each digital printing unit 4 may be applied to different portions of the transfer blanket 6 to form a single upholstery 7. In addition, the trim material from two or more digital printing units 4 may at least partially overlap or cover each other to form the trim 7.

Alternatively, in another embodiment, two or more digital printing units 4 may deliver the same color of trim material to the transfer blanket 6. The first digital printing unit 4A may form part of the decor 7 in a first color. The second digital printing unit 4B may form a second portion of the decoration 7 in one or more of the first color and the second color. In one embodiment, by dividing the composition of the decor 7 between the two

digital print units

4A, 4B, the decorator 2 of the present invention can operate at a faster rate than decorators having a single digital print unit for forming the decor. More specifically, the transfer blanket 6 is able to pass through the

digital printing units

4A, 4B at a faster rate than if a single digital printing unit 6 were used to form the entire decoration 7.

In another embodiment, the one or more digital printing units 4 are operable to transfer multiple colors or types of trim material onto the transfer blanket 6. For example, in one embodiment, at least one of the digital printing units 4 may transfer a decorative material of at least one color of cyan, magenta, yellow, and black (or a "key color") onto the transfer blanket 6 to form the decoration 7.

In one embodiment, each digital printing unit 4 forms a complete decoration 7 on the transfer blanket 6. In another embodiment, each digital printing unit 4 may form a portion of the decoration 7 on the transfer blanket 6. Thus, the first digital printing unit 4A delivers the trim material onto the transfer blanket 6 to form a first portion of the trim 7. The second digital print unit 4B delivers additional trim material onto the transfer blanket 6 to form a second portion of the trim 7. The third and fourth

digital printing units

4C, 4D may form third and fourth parts of the decor 7. Each portion of the trim 7 may include one or more colors or types of trim material.

Referring now to FIG. 2A, in one embodiment, at least one of the digital printing units 4 is an inkjet print head 41. The inkjet print head 41 generally includes a reservoir or source 51 of ink 43 and a nozzle 45. The nozzles 45 are operable to spray or jet ink 43 onto the transfer blanket 6. In one embodiment, the inkjet print head 41 may eject up to about 7.74 hundred million drops of ink 43 per second. In another embodiment, the inkjet print head 41 includes five color channels. In another embodiment, inkjet printhead 41 includes 10 rows of nozzles 45, each row having up to 70400 nozzles, for printing five colors of ink 43 at a density of up to 1600 dots per inch.

Any suitable ink 43 may be used in conjunction with the inkjet print head 41 of the present invention. In one embodiment, the ink jet print head 41 may form a predetermined image or indicia on the outer surface 24 of the metal container 22 using an ink having nanoparticles. In another embodiment, the ink jet print head 41 can use ink 43 having a particle size of no greater than about 500 nanometers. In one embodiment, the ink 43 comprises a photo-curable ink, such as, but not limited to, an ultraviolet curable ink. In another embodiment, the ink 43 comprises a water-based ink that is curable using thermal energy. In another embodiment, the ink 43 comprises an oil-based ink that is cured by thermal energy. In one embodiment, the oil-based ink comprises a mineral ink.

Optionally, the inkjet print head 41 is configured to change the viscosity of the ink 43. More specifically, the inkjet print head 41 may adjust the viscosity of the ink 43 by one or more of changing the temperature of the ink 43 and activating an initiator in the ink 43. In one embodiment, changing or adjusting the viscosity of the ink 43 changes the size of the dots or droplets of ink 43 that form the decoration 7 on the transfer blanket 6. In this way, inks from different inkjet print heads 41 can be delivered to locations on the transfer blanket 6 adjacent to each other to form the decoration 7 while the inks are in a wet or uncured state. Alternatively or additionally, changing the viscosity of the ink 43 can prevent accidental or accidental movement of dots or drops of ink 43 on the transfer blanket 6. Thus, multiple inks can be delivered from different inkjet print heads 41 onto the transfer blanket 6 without curing before additional inks are delivered onto the transfer blanket. By adjusting the viscosity of the ink, the ink jet print head 41 can "pre-dot" or "spot cure" the ink 43 onto the transfer blanket. More specifically, in one embodiment, the viscosity of the ink may be adjusted to at least partially cure or dry the ink before or after contact with the transfer blanket 6.

The inkjet print head 41 may include a temperature control device 5B, the temperature control device 5B being configured to heat or cool the ink 43 to a predetermined temperature. Alternatively, the temperature control device 5B may be in contact with the ink 43 or immersed in the ink 43. In another embodiment, the temperature control device 5B may be configured to heat or cool the ink supply 51. For example, in one embodiment, the ink source 51 is a container or hose. The temperature control device may be configured to heat or cool the outer surface of the ink supply 51 such that the ink 43 within the ink supply 51 is heated or cooled to a predetermined temperature.

In one embodiment, at least one light emitter 47 is associated with the inkjet print head 41. The light emitter 47 is operable to emit light 55. The light 55 has a predetermined wavelength selected to activate one or more initiators in the ink 43. The initiator changes the viscosity of the ink 43 when activated by contact with light 55. In one embodiment, the light 55 is ultraviolet light.

In one embodiment, the ink 43 includes at least two initiators. The first initiator may increase the viscosity of ink 43 when activated by light 55A of the first wavelength emitted by first light emitter 47A. Alternatively or additionally, the ink 43 may include a second initiator. The second initiator may reduce the viscosity of ink 43 when activated by light 55B of a second wavelength emitted by second light emitter 47B.

In one embodiment, the ink source 51 comprises a container or hose that is transparent or translucent to the light 55. Optionally, at least a portion of the ink supply 51 is transparent or translucent to the light 55 generated by the light emitter 47. Alternatively, the ink source 51 may include a window or aperture 53. The window 53 may be selected to transmit light 55 from the light emitter. The light emitter may be aligned with the aperture 53 such that light 55 can enter the ink supply 51 and illuminate the ink 43 and activate the viscosity inducing agent therein.

Alternatively, the light emitter 47C may be oriented to direct light 55C that illuminates the ink droplets 43 discharged from the nozzle 45. The light 55C can be directed to illuminate the ink drops 43 before the ink reaches the transfer blanket 6. In this manner, the light emitter 47C can alter the viscosity of the ink drops 43 before the ink contacts the transfer blanket 6.

Alternatively or additionally, in one embodiment, light emitters 47D are oriented to direct light 55D to transfer felt 6. The light 55D may have a predetermined wavelength to activate the initiator in the ink 43 when the ink is on the transfer blanket 6. Accordingly, the light emitter 47D is configured to change the viscosity of the ink on the transfer blanket.

In one embodiment, at least one of the digital printing units 4 comprises an inkjet printing unit 41. Suitable inkjet print heads 41 are available from a variety of suppliers including, but not limited to, Xaar, Konica Minolta, FujiFilm, Kyocera, Tonejet, and Memjet Ink.

Referring now to fig. 2B, in one embodiment, one or more of digital print units 4 may include an electrophotographic system 40. The electrophotographic system 40 may generally include one or more of a conductor 42 (also referred to as an "electrophotographic plate"), an "emitter" or charging element 44, an exposure element 46, and a development unit 48. In one embodiment, the electrophotographic system 40 further includes one or more of a cleaning element 14A and a transfer charging element 50. Electrophotographic systems and toners for use in conjunction therewith are generally described in U.S. patent application publication 2006/0068313, U.S. patent 4,743,926, U.S. patent 5,018,640, U.S. patent 5,065,183, U.S. patent 5,750,303, U.S. patent 6,818,369, U.S. patent 7,666,564, and U.S. patent 7,939,235, the contents of each of which are incorporated herein by reference in their entirety.

The conductor 42 is in a predetermined alignment with respect to the path of the transfer blanket 6 of the decorator 2. In one embodiment, the conductor 42 rotates while remaining in contact with the outer surface of the transfer blanket 6. Alternatively, in another embodiment, the conductor 42 is rotated at a position immediately adjacent to the outer surface of the transfer blanket 6 without contacting the transfer blanket 6. Regardless of the arrangement, conductor 42 is oriented to transfer toner 52 to transfer felt 6. In one embodiment, the conductor 42 has a generally cylindrical shape. In another embodiment, the conductor 42 has the shape of a loop or a band, which may be circular or have a serpentine shape. The loop of conductor 42 may extend around one or more rollers and tensioning devices as described herein.

In one embodiment, conductor 42 comprises a photoconductive material. More specifically, in one embodiment, the surface of the conductor 42 is electrically conductive when exposed to light. In the absence of light, the surface is not conductive. Suitable photoconductive materials are known to those skilled in the art. In one embodiment, conductor 42 comprises one or more layers of inorganic material. The inorganic photoconductive material may include at least one of the following materials: silicon, selenium, cadmium sulfide, zinc oxide, and the like. In another embodiment, conductor 42 includes at least one layer of organic material. Optionally, the organic photoconductive material includes one or more of polyvinylcarbazole, phthalocyanine, and the like.

In operation, the charging element 44 or "emitter" provides charge to the conductor 42. In one embodiment, the charging element 44 generates a corona discharge to charge the conductor 42. A decoration is then formed on the outer surface of the conductor 42. In one embodiment, the charging element 44 has a generally cylindrical shape. In another embodiment, the charging element 44 is in contact with the conductor 42 when the charging element 44 charges the conductor.

Forming the decoration includes exposing selected portions of the conductor to light. More specifically, the exposure element 46 selectively exposes portions of the conductor 42. The exposure element 46 can direct light to selectively impinge a predetermined portion of the outer surface of the conductor 42 to trace the shape of the decoration. As the charge provided by the charging element 44 is carried away by the conductive surface of the conductor, the portion of the conductor 42 exposed by the exposure element 46 is electrically neutralized. The other portions of the conductor 42 not exposed to light remain charged. The remaining charged regions of the conductor 42 form a latent decoration on the conductor 42. Thus, exposure element 46 can discharge selected portions of conductor 42. In one embodiment, the latent electrostatic decoration is electrostatic.

In one embodiment, the decoration formed by exposure element 46 is received from control system 12 of decorator 2. More specifically, in one embodiment, control system 12 sends a signal to exposure element 46. The signal causes the exposure element 46 to expose a predetermined portion of the conductor 42 to form a latent decoration. In another embodiment, exposure element 46 comprises a laser or other light-generating device.

The developer unit 48 converts the latent decoration into a visible decoration 7. In one embodiment, the developing unit 48 includes toner 52. Toner 52 is attracted to the charged areas of the latent image decoration formed by the exposed elements 46. In this way, the toner 52 forms the decoration 7 visible on the conductor 42. Optionally, the developing unit 48 includes a roller 49 that delivers toner 52 to the conductor 42. In another embodiment, the developing unit 48 includes a blade for adjusting the amount or thickness of toner 52 on the roller 49. Optionally, the toner 52 on the roller 49 is limited by the blade to a thickness of no greater than about 0.3 millimeters.

In one embodiment, the toner 52 includes charged particles that adhere to the underlying decoration. In one embodiment, the toner 52 may be charged. In another embodiment, toner 52 has a charge with a polarity opposite to the polarity of the charge of conductor 42 generated by charging element 44. Alternatively, the developing unit 48 may use wet or dry toner to develop the decoration. In one embodiment, dry toner uses only toner 52. In another embodiment, dry toner includes a carrier that delivers toner to conductor 42. In one embodiment, the carrier comprises particles. The carrier particles may be larger than the particles of toner 52.

The carrier of toner 52 may include one or more of iron powder, ferrite, magnetite, and glass beads. These supports may be coated with a resin. The resins may include, but are not limited to, polyfluorocarbon, polyvinyl chloride, polyvinylidene chloride, phenolic resins, polyvinyl acetal, and silicone resins. In one embodiment, the mixing ratio of toner to carrier is about 1.5-10.0 parts by weight toner to 52-100 parts by weight carrier. In one embodiment, the carrier particles are magnetic.

Toner material 52 may include particles of one or more materials. In one embodiment, the toner includes carbon powder and iron oxide. In another embodiment, toner material 52 includes at least one of a binder resin, a colorant, a polar resin, and a release agent. In one embodiment, each color is generally present in an amount of about 0.1 to 50 parts by weight, based on 100 parts by weight of the binder resin. Alternatively, the toner material 52 may include polymers such as, but not limited to, styrene acrylate copolymers, polyester resins, and styrene butadiene copolymers.

In one embodiment, external additives are added to toner 52. The external additive may include at least one of inorganic or organic particles. The external additive may be surface-treated to improve hydrophobicity and prevent the fluidity and charging performance of the toner 52 from deteriorating in a high humidity environment. Specific preferred examples of the surface treatment agent include, but are not limited to, coupling agents (e.g., silane coupling agents; titanate coupling agents and aluminum coupling agents); a silicone oil; higher fatty acids; and a fluorine compound.

The inorganic particles of the external additive may include metal oxides, metal carbides, metal nitrides, and metal carbonates. In one embodiment, the inorganic particles include, but are not limited to, silica, alumina, titania, barium titanate, magnesium titanate, calcium titanate, strontium titanate, zinc oxide, tin oxide, quartz sand, clay, mica, gray sand, diatomaceous earth, chromium oxide, cerium oxide, red iron oxide, antimony trioxide, magnesium oxide, zirconium oxide, barium sulfate, barium carbonate, calcium carbonate, silicon carbide, and silicon nitride. The external additive may include organic particles such as, but not limited to, one or more of styrene, a copolymer of methacrylate and acrylate, which may be prepared by soap-free emulsion polymerization, suspension polymerization or dispersion polymerization, and a condensation thermosetting resin such as silicone resin, benzoguanamine resin and nylon.

Charge control agents may be included as a component of the toner material 52 of the present invention. The charge control agent may include known charge control agents. For example, the charge control agent may include one or more of the following: nigrosine dyes, triphenylmethane dyes, chromium-containing metal complex dyes, chelate compounds of molybdic acid, rhodamine dyes, alkoxyamines, quaternary ammonium salts (including fluorine-modified quaternary ammonium salts), alkylamides, phosphorus and phosphorus-containing compounds, tungsten and tungsten-containing compounds, fluorine-containing activators, metal salts of salicylic acid derivatives, and the like. In one embodiment, the content of the charge control agent is preferably about 0.1 to 10 parts by weight, more preferably about 0.5 to 3 parts by weight, based on 100 parts by weight of the binder resin. The charge control agents described above may be used in toner material 52 individually or in any combination. In addition, the amount of charge control agent used may vary depending on the color of toner material 52.

Toner material 52 may be formed from particles of various sizes. In one embodiment, the toner particles have an average particle size of less than about 16 microns. In another embodiment, the toner particles have an average particle size of less than about 10 microns. The particle size of the toner may be greater than about 6 microns. Alternatively, the particle size of the toner 52 is between about 6 microns to about 18 microns.

In one embodiment, electrophotographic system 40 may transfer one or more colors of toner material 52 to transfer felt 6. For example, in one embodiment, the electrophotographic system 40 may transfer one to four colors of toner materials 52. In one embodiment, toner material 52 includes one or more of cyan colorant, magenta colorant, yellow colorant, and black colorant. Alternatively, each color of toner material 52 has a different polarity. More specifically, the first toner may have a first polarity, the second toner may have a second polarity, the third toner may have a third polarity, and the fourth toner may have a fourth polarity. In this manner, the electrophotographic system 40 may form a decoration 7 that includes toner materials 52 of a plurality of different colors.

When the conductor 42 rotates adjacent to the transfer belt 6, the toner 52 is transferred from the conductor onto the transfer belt. In one embodiment, optional transfer charging element 50 generates an electrical charge that attracts toner 52 from conductor 42 to transfer felt 6. In one embodiment, transfer charging element 50 generates a corona discharge to attract toner 52. The toner 52 forms the decoration 7 on the felt 6. The decoration 7 may then be transferred to the container outer surface 24, as described herein.

Optionally, the conductor 42 is subsequently cleaned using the cleaning system 14A. More specifically, cleaning system 14A removes any toner particles 52 that are not transferred to felt 6. In one embodiment, cleaning system 14A has a generally cylindrical shape. Additionally, in one embodiment, the cleaning system 14A may also discharge the conductor 42. For example, in one embodiment, cleaning system 14A generates light to expose the entire width of conductor 42. Thus, any remaining charge of the conductor 42 is discharged by the cleaning system 14A so that the conductor 42 can subsequently receive a new charge through the charging element 44.

Referring again to fig. 1, the decoration 7 formed by the digital printing unit 4 may comprise any combination of letters, numbers, symbols and images of any size, arranged in any order or orientation. The decoration is formed of a decorative material (e.g., ink or toner), and may be of a single color or formed of multiple colors. Further, each decoration may be unique. For example, the decoration 7A may be different from one or more of the

decorations

7B, 7C. Thus, it is economically feasible to produce small batches of decorated metal containers 28 with different images 30 using the decorator 2 of the present invention.

The transfer blanket 6 of the decorator 2 can be of any size or shape. In one embodiment of the invention shown in fig. 1, the transfer blanket 6 includes a plurality of individual transfer blanket sections 6A interconnected with a support member, such as a blanket wheel 18. However, in another embodiment, a single transfer felt 6 may be disposed on the felt wheel 18. In another embodiment, the transfer blanket 6 may comprise a single sleeve or cylinder that surrounds the circumference of the blanket wheel 18. In addition, the decorator 2 may use a non-circular continuous transfer blanket. Alternatively, the length of each transfer felt section 6A is not less than the circumference of the metal container 22.

The transfer blanket 6 of embodiments of the present invention may be formed of a material selected to receive and retain the decorative material from the digital printing unit 4. In one embodiment, transfer blanket 6 comprises one or more of a face, a first fabric layer, a compressible layer, and a second fabric layer, as described in the "offset blanket" document (hereinafter "offset") which may be found in http:// www.offsetprintingtechnology.com/sub-categories/blanket-for-offset-printing (last visit date 2016, 4/7/2016), the contents of which are incorporated herein by reference in their entirety. The face may comprise a relatively thin rubber material, such as Nitrile Butadiene Rubber (NBR). It will be appreciated by those skilled in the art that nitrile rubbers (NBR) are a family of unsaturated copolymers of 2-acrylonitrile with various butadiene monomers (1, 2-butadiene and 1, 3-butadiene). NBR is also known as Buna-N, Perbunan, nitrile rubber, Nipol rubber, sodium Carlan and European rubber.

In another embodiment, the transfer blanket 6 may comprise a photopolymer material or a compound that at least partially comprises polymethylene saturated chains. Suitable materials for the transfer blanket 6 are described in U.S. patent application publication 2015/0217559, the contents of which are incorporated herein by reference in their entirety.

In operation, the transfer blanket 6 rotates in a first direction. The digital printing unit 4 transfers or sprays the upholstery material onto the outer surface portions of the transfer blanket 6 to form the upholstery 7. In one embodiment, the transfer blanket 6 is continuously moving at a predetermined rate. In another embodiment, the transfer blanket 6 is indexed such that the transfer blanket 6 pauses for a predetermined amount of time in the vicinity of one or more digital print units 4. In this manner, the transfer blanket 6 may be substantially stationary while the digital printing unit 4 forms the decoration 7 on the transfer blanket 6. Regardless of the form, in another embodiment, the rate of movement of the transfer blanket 6 relative to the digital print unit 4 is selected by the control system 12. Thus, the control system 12 can control the rate and position of the decoration 7 formed by the digital printing unit 4 and the movement of the transfer blanket 6 so that the decoration is subsequently transferred to the metal container 22. In one embodiment, the control system 12 sends a signal to an actuator or drive unit of the felt wheel 18 to control the rate of movement of the felt wheel 18.

Optionally, the decor 7 may be cured (or at least partially cured) by one or more curing units 16. In one embodiment, each digital print unit 4 has an associated curing unit 16. In this manner, the trim material sprayed (or delivered) by each digital printing unit 4 at least partially cures or sets on the transfer blanket before the subsequent digital printing unit 4 delivers additional trim material onto the transfer blanket 6 to form the trim 7. In another embodiment, only one curing unit 16D cures all of the trim material applied by the

digital printing units

4A, 4B, 4C, and 4D. The curing unit 16D may be located between the final digital print unit 4D and the image transfer portion 25 of the decorator. In one embodiment, the curing unit 16 generates light of a selected wavelength to at least partially cure or solidify the trim material conveyed by the digital printing unit 4. In one embodiment, the curing unit 16 includes an ultraviolet or ultraviolet LED curing light. In another embodiment, the curing unit 16 generates thermal energy to cure the trim material. Alternatively, the curing unit 16 may generate infrared rays. In one embodiment, the curing unit 16 is adapted to cure the toner 52. In another embodiment, the curing unit 16 is adapted to cure the ink 43. Alternatively, the curing unit 16 can cure the ink 43 and the toner 52.

The feeding unit 8 moves the metal container 22 to a predetermined position with respect to the transfer blanket 6. Then, the outer surface portion 24 of the metal container 22 is rotated while being kept in contact with the outer surface of the transfer blanket 6. In this way, the decorative material (e.g., ink or toner) forming the decoration 7 on the outer surface of the transfer blanket is transferred from the transfer blanket 6 onto the metal container.

In one embodiment, feed unit 8 may rotate metal container 22 such that outer surface 24 is in a predetermined alignment with respect to decorator 2. More specifically, in one embodiment, the feed unit 8 may detect registration marks on the metal container 22. At this time, the feeding unit 8 may rotate the metal container 22 so that the alignment mark is in a predetermined alignment state with respect to the transfer blanket 6. In this manner, container exterior surface 24 will be in predetermined alignment with decorator 2. Optionally, the sensor detects the alignment marks. In one embodiment, the registration marks are marks printed on the metal container 22. In another embodiment, the alignment mark is a protrusion, extension or depression formed on the metal container. One example of a feed device that may be used in conjunction with the decorator 2 of the present invention is illustrated in U.S. patent 9,027,733, the contents of which are incorporated herein by reference in their entirety. In one embodiment, control system 12 receives information regarding alignment marks. The control system 12 may then determine whether the metal container is in a predetermined alignment. If the metal container is not in the predetermined alignment state, the control system 12 may send a signal to the feeding unit 8 to rotate the metal container to the predetermined alignment state.

In one embodiment of the present invention, the feeding unit 8 operates at a circulation rate (or speed) different from the rotation speed of the transfer blanket 6. More specifically, in decorator 2A having multiple digital print units 4 and/or segmented transfer blankets 6A (as shown in one embodiment of the present invention in fig. 1), the processing rate of metal containers 22 may be different than the print speed of digital print units 4. In this manner, decorator 2 is able to decorate metal container 22 at a faster rate than prior art inkjet container decoration systems or electrophotographic decoration systems using unique decorations 7 formed by digital printing techniques (including inkjet printer 41 or electrophotographic system 40).

In one embodiment, the individual transfer felt sections 6A are interconnected with a felt wheel 18 so that the transfer felt sections 6A can change speed to match the rotational speed of the metal containers 22 in the feed unit 8. Thus, the transfer felt section 6A may be accelerated or decelerated to match the rotational speed of the container outer surface 24 to transfer the image 7 to the container outer surface portion 24. In one embodiment, the transfer felt section 6A is releasably interconnected with the felt wheel 18. Alternatively, the transfer felt section 6A is separated from the felt wheel 18 after the upholstery material is transferred to the metal container 22. In one embodiment, the digital printing unit 4 transfers the trim material to the transfer felt section 6A as the transfer felt section is separated from the felt wheel 18. In another embodiment, the number of transfer blanket sections 6A is greater than the number of transfer blanket stations on the blanket wheel 18. The transfer felt section 6A may follow two or more paths through the decorator 2 as it separates from the felt wheel 18. The first set of transfer blanket sections 6A may travel along a first path to receive the trim material from the first set of digital printing units 4. The second set of transfer blanket sections 6A may travel along a second path and receive the trim material from the second set of digital printing units. In one embodiment, the transfer felt section 6A is returned to the felt wheel 18 after receiving the trim material from the digital printing unit. Optionally, in one embodiment, each transfer felt segment 6A is interconnected with the felt wheel 18 during transfer of the trim material to the metal container 22. In this manner, after the image 7 is formed on the transfer blanket section 6A, the transfer blanket section 6A may be accelerated or decelerated to match the speed of the outer surface portion 24 of the metal container 22.

In another embodiment of the invention, each individual felt section 6A is disposed on a mandrel that is interconnected with a felt wheel 18. Each spindle is independently rotatable about a spindle axis that is substantially parallel to the axis of the felt wheel 18. In this manner, each individual felt section 6A may be rotated on a mating mandrel at a first rate as the digital print unit 4 forms the decor 7 on the transfer felt section 6A. Furthermore, during the transfer of the decoration 7 to the metal container 22 positioned by the feeding unit 8, each individual felt section 6A can rotate on its own mandrel at a second rate. The second speed of rotation of the individual felt section 6A may be selected to match the speed of rotation of the metal holder 22.

In another embodiment, the individual transfer blanket sections 6A may be separated by a variable distance 15. Thus, two adjacent transfer blanket sections 6A may be separated by a distance 15A near one or more digital print units 4. Adjacent transfer blanket sections 6A may be separated by a second distance 15B near the feed unit 8. In one embodiment, the first distance 15A is less than the second distance 15B. Alternatively, the first distance 15A may be less than about 1 inch such that the transfer blanket section 6A passes substantially continuously through the digital print unit 4. In this manner, the transfer blanket section 6A has a first linear velocity near the digital print unit 4 and a second linear velocity near the feed unit 8. In one embodiment, the first linear velocity is slower than the second linear velocity. Thus, the transfer blanket section 6A may be moved at a slower speed near the digital print unit 4. In this example, the transfer blanket section 6A moves at a relatively fast speed in the vicinity of the feeding unit 8 and the metal container 22. Thus, the transfer felt section 6A can be accelerated to match the radial velocity of the outer surface portion 24 of the metal container 22 at the feeding unit 8.

In one embodiment, the transfer felt section 6A is interconnected with the felt wheel 18 such that the transfer felt section 6A is movable independently of the constant rotation of the felt wheel 18. In another embodiment, the transfer blanket segments are interconnected to the blanket wheel 18 by one or more pivot joints, rollers, cams, and springs. In this manner, the transfer felt section 6A may be stopped at a first location and accelerated at another location. With the dwell and predetermined positions, the transfer blanket section 6A may dwell for a longer period of time during transfer of the image to the metal container 22 and near one or more elements of the decorator (e.g., one or more of the digital print unit 4, curing unit 16, feed unit 8) at the cleaning system 14.

Referring now to fig. 1A, in one embodiment of the invention, a transfer blanket section 6A is interconnected with a blanket wheel 18 by a blanket support 20A. Each felt section 6A is connected to one end of a felt support 20A extending from the felt wheel. The felt support 20A positions the felt section 6A at a predetermined distance 21 from the felt wheel 18. Optionally, felt supports 20A project radially from felt wheel 18. In one embodiment, the felt support 20A is oriented substantially perpendicular to the axis about which the felt wheel 18 rotates.

The felt support 20A may change the position of its associated felt section 6A relative to the felt wheel 18. In one embodiment, the felt support 20A is operable to vary the distance 21 between the felt wheel 18 and the felt section 6A. Thus, as the felt wheel 18 rotates, the felt support 20A may increase and decrease the distance 21 between the felt wheel and the felt segment. In this manner, each felt section 6A may have an elliptical path (or track) around the felt wheel 18. Further, the relative speed of the felt section 6A may be varied relative to the digital print unit 4 and the image transfer location 25. Further, transfer blanket 6A may have a first pitch 15A in a first position of decorator 2A and a second pitch 15B in a second position of decorator 2A. Alternatively, the first pitch 15A near the digital printing unit 4 is smaller than the second pitch 15B near the image transfer position 25.

In one embodiment, the felt section 6A is a first distance 21A from the felt wheel 18 proximate the image transfer location 25. The felt section 6A is a second distance 21B from the felt wheel 18 near the digital print unit 4. In one embodiment, the first distance 21A is greater than the second distance 21B. Thus, in one embodiment, during transfer of the trim material to the transfer blanket 6A, the transfer blanket 6A moves faster relative to the metal container 22 being decorated at the image transfer location 25 and slower relative to the digital printing unit 4.

The felt support 20A may vary the distance 21 between the felt wheel 18 and the felt section 6A in a variety of ways. In one embodiment, the felt support 20A may be at least partially retracted into the felt wheel 18. For example, in one embodiment, the felt wheel 18 includes a recess or hole (not shown for clarity) associated with each felt support 20A. A portion of the felt support 20A may be selectively retractable into or extendable from a corresponding aperture of the felt wheel 18. In this manner, the distance 21 between the felt section 6A and the felt wheel 18 can be adjusted as the wheel rotates.

The felt section 6A may have a curved or arcuate shape. Optionally, in one embodiment, the felt support 20A is configured to adjust the shape of the felt section 6A as the felt section 6A rotates about the felt wheel 18. For example, as the felt support 20A extends the felt section 6A distally from the felt wheel 18 (e.g., proximate the image transfer location 25), the felt support may change the shape of the felt section 6A to be flatter. Alternatively or additionally, the felt support may adjust the shape of the felt section to be more arcuate and less planar as the felt support moves the felt section 6A closer to the felt wheel.

Alternatively or additionally, in one embodiment, the felt support 20A may have an adjustable length. For example, the felt support 20A may include at least two sections 37-39. The segments are telescopic so that the length of each felt support 20A is adjustable. In one embodiment, the at least two segments include a first segment 37 and a second segment 38. The second section 38 may fit at least partially within the first section 37. Alternatively, the felt support 20A may include a third section 39. The second section 38 may fit at least partially within the third section 39, and the third section 39 may extend from the first section 37 or retract into the first section 37.

Referring now to FIG. 1B, in another embodiment of the invention, a felt support 20B interconnected with the felt wheel 18 may pivot relative to the felt wheel. In this way, the blanket support 20B can move the transfer blanket 6A at a different speed relative to the digital printing unit 4 than the metal container 22 that will be decorated at the image transfer location 25. In one embodiment, the blanket support 20B pivots or moves the transfer blanket section 6A relative to the digital print unit 4 at a first speed. The felt support 20B can move the transfer felt section 6A relative to the metal container 22 at a second speed at the image transfer location 25. In one embodiment, the first speed is less than the second speed. In this manner, the blanket support 20B may move the transfer blanket section 6A relatively slowly with respect to the digital printing unit 4 and relatively quickly with respect to the metal container 22 during transfer of the decoration at the transfer location 25.

In one embodiment, the felt support 20B may be pivotally interconnected with the felt wheel 18 by a pivot joint 29. In this manner, the felt support 20B may pivot at various angles relative to the felt wheel. For example, the felt support 20B with image 7B is shown pivoted about pivot joint 29 so that image 7B is proximate the felt support with image 7A. In this manner, the felt segment with image 7B is spaced a distance 15B from the felt segment with image 7A. The distance 15B between the felt segments is less than the distance 15A when the felt support 20B protrudes (or does not pivot) substantially radially relative to the felt wheel (e.g., near the digital print unit 4). Alternatively, the felt support 20B may be rotated about-45 to about +45 relative to the radius of the felt cylinder.

In one embodiment, the felt section 6A is connected to the exterior of the felt support 20B by a second pivot joint 31. Thus, as the felt wheel 18 rotates, the outer surface of the felt section 6A may pivot to a predetermined orientation. In one embodiment, the felt section 6A is configured to rotate relative to the felt support 20B about the second pivot joint 31 such that an outer surface of the felt section is in a predetermined orientation relative to one or more of the cleaning system 14, the digital printing unit 4, the curing unit 16, the feeding unit 8, the cleaning system 14, and the temperature control device 5.

In one embodiment, the felt support 20B includes two or

more sections

37, 38 that are pivotally connected. More specifically, the felt support 20B may include a first section 37 interconnected with the felt wheel 18. The second section 38 of felt support 20B interconnects with transfer felt section 6A. Optionally, the first and

second sections

37, 38 of the felt support 20B are pivotally interconnected. For example, the first section 37 may be connected to the second section 38 by a third pivot joint 33. Optionally, the felt support 20B is operable to vary the distance between the transfer felt section 6A and the felt cylinder 18 in a manner similar or identical to the felt support 20A described in connection with fig. 1A.

Referring again to fig. 1, in one embodiment of the present invention, the feeding unit 8A has a substantially cylindrical shape. Alternatively, the feeding unit 8A may include a plurality of stations 9 to receive and support the metal container 22 at a predetermined position with respect to the transfer blanket 6. In one embodiment, the feed unit 8 is operable to rotate the metal container 22 such that the outer surface 24 moves at a rate substantially equal to the rotational speed of the transfer blanket 6. In this way, the dynamic influence on the transfer blanket 6 can be minimized.

In one embodiment, the feeding unit 8A includes a spindle 11 for supporting and/or rotating the metal container 22. Alternatively, the mandrel 11 may be associated with the station 9. In one embodiment, each spindle 11 is rotatable about an axis substantially parallel to the axis of rotation of the feed unit 8A. In one embodiment, the mandrel 11 with the metal container 22 may be rotated such that a predetermined outer surface portion of the metal container 22 is in contact with the transfer blanket 6A. Alternatively, a servo drive or other mechanical or electrical means may be used to rotate the spindle 11. In one embodiment, each spindle has an associated servo drive. In another embodiment, the servo drive is controlled by signals from the control system 12. In another embodiment, the spindle 11 has a matching torque motor.

Alternatively, the spindle 11 may rotate in response to a mechanical force. In one embodiment, the rotation of the spindle of the feed unit 8A is controlled by a belt or chain interconnected with the felt wheel 18. In this way, the rotation of the mandrel 11 and the metal container 22 thereon can be synchronized with the rotation of the transfer blanket 6A.

Alternatively, the mandrel 11 moves the metal container 22 into contact with the transfer felt section 6A at the image transfer location 25. In one embodiment, the mandrel 11 of the feeding unit 8A is at least partially located inside the metal container 22 supported by the feeding unit 8A. In this manner, the mandrel can support the side wall portions of the metal container 22 during contact of the metal container with the transfer felt section 6A. The mandrel 11 may be configured to force the outer surface 24 of the metal container 22 against the transfer felt so that the trim material is transferred to the metal container. In another embodiment, the mandrel 11 is in contact with an outer surface portion of the metal container 22. Alternatively, the mandrel may support the metal container 22 by contacting the closed end wall portion of the metal container 22.

After the decoration 7 is transferred to the metal container 22, the transfer felt section 6 may optionally be cleaned by a cleaning system 14. For example, in one embodiment of the invention, the cleaning system 14 removes any residual ink or toner from the outer surface of the transfer felt section 6 before the digital printing unit 4 applies new trim material to form a new trim 7 on the transfer felt section 6. In one embodiment, the cleaning system 14 contacts the outer surface of the transfer felt section 6 during cleaning. In another embodiment, the cleaning system 14 cleans the transfer felt section 6 in a non-contact manner.

Decorator 2 may optionally include a temperature control device 5A. The temperature control device 5A is operable to adjust the temperature of the transfer felt section 6A. Specifically, the temperature control device 5A may heat or cool the mat 6A to a predetermined temperature. In this manner, the temperature control device 5A can change the characteristics of the trim material (e.g., ink) applied to the felt section 6A. More specifically, the viscosity of the ink can be adjusted by changing the temperature of the felt section 6A. The temperature of the felt section 6A may also change other characteristics of the ink applied by the digital printing unit 4. For example, varying the temperature of the felt section can: affecting the flow of ink on the felt section, changing the thickness of the ink on the felt section, and changing the appearance of the ink. In one embodiment, the temperature of the felt section can be adjusted to vary the size of the ink drops used to form the decoration 7. The temperature of the felt section 6A may also be adjusted by the temperature control device 5A to thermally pre-tack or at least partially set or cure the ink-containing finishing material applied to the felt section. For example, heating the felt section to a predetermined temperature may thermally cure or "pre-set" the ink. In one embodiment, the ink 43 transferred from the digital printing unit 4 (e.g., the inkjet print head 41) onto the felt section is at least partially thermally cured upon contact with the felt section 6A heated to a predetermined temperature. More specifically, the temperature control device 5A may adjust the temperature of the transfer blanket section 6A such that the first ink 43 delivered to the transfer blanket section by the first digital print unit 4A is at least partially cured or solidified prior to the second digital print unit 4B delivering the second ink 43 to the transfer blanket section.

In one embodiment, the temperature control device 5A comprises at least one roller. The roller is aligned relative to the blanket wheel 18 so that each transfer blanket section 6A is contacted by the roller. The temperature control device 5A may heat or cool the felt section. In one embodiment, the temperature control device 5A is interconnected with a fluid source. The fluid source may include a heating element and a cooling element. Alternatively, the fluid may be water. In another embodiment, the fluid is oil or gas. Alternatively or additionally, the temperature control device 5A may comprise an electrical heating element.

In one embodiment, the control system 12 communicates with the temperature control device 5A. The control system may send a signal to the temperature control device 5A to adjust the temperature of the felt section 6A.

In one embodiment, the temperature control device 5A is positioned in contact with the outer surface of the transfer felt section 6A, as generally shown in fig. 1. The temperature control device 5A may be located anywhere around the circumference of the blanket wheel 18. In one embodiment, a temperature control device 5A is located between the image transfer location 25 and the first digital printing unit 4A. Other locations of the temperature control device 5 are also contemplated. In one embodiment, the temperature control device 5 is associated with a felt wheel 18. More specifically, the blanket wheel 18 may have a temperature control device 5 associated with each transfer blanket segment 6A. For example, one temperature control device may be provided in the blanket wheel 18 at each location that will interconnect a transfer blanket segment. In one embodiment, the temperature control device 5A is operable to regulate the temperature of the felt section 6A in a non-contact manner. For example, the temperature control device 5A may emit infrared light to adjust the temperature of the felt section.

The metal container 22 can be transported to the feeding unit 8 by the conveyor belt 10. In one embodiment of the invention, the feeding unit 8 receives the metal container 22 from an upstream apparatus 26. The metal container 22 may be a beverage container (e.g., a beverage can or beverage bottle), an aerosol container, a food can, or a container for any other type of product. The upstream apparatus 26 may comprise a draw line or a punch line. An example of a known drawn container production line Is generally shown and described in the literature "in spherical Beverage Can factories", which Is found in http:// www.ball.com/Ball/media/Ball/Global/Downloads/How _ a _ Ball _ Metal _ coverage _ Can _ Is _ master. pdf (the last visit date Is 2016, 4 months and 30 days), the contents of which are incorporated herein by reference in their entirety. Methods and apparatus for forming metal containers on a stamping line are described in U.S. patent application publication 2013/0068352 and U.S. patent application publication 2014/0298641, the contents of which are incorporated herein by reference in their entirety.

Optionally, in another embodiment, the feed unit 8 receives the end caps 34 from an end cap orientation system. Embodiments of end cap orientation and decoration systems are described in U.S. patent 9,259,913 and U.S. patent 9,340,368, the contents of which are incorporated herein by reference in their entirety. At this time, the feeding unit 8 moves the end cap 34 into contact with the transfer blanket 6 of the decorator 2.

In one embodiment of the present invention, the upstream equipment 26 includes a first printing press or decorator. The first decorator may form a first decoration 23 on an outer surface portion 24 of the metal container 22. In one embodiment, the first decoration 23 includes a primer layer. In another embodiment, the first decoration 23 may comprise one or more of text, numbers, and images.

In one embodiment, the first decoration 23 includes a window or void portion formed on the metal container 22. The decorator 2 of the present invention is operable to form a decor 7, which decor 7 is subsequently transferred onto a metal container such that the decor 7 is aligned with the first decor 23 and the window. For example, the first decoration 23B may include an image (e.g., a jersey), an example of which is shown on the container 28B. The decorator 2 can form the decoration 7 on the transfer blanket 6, which decoration 7 is then transferred to the metal container 28B. The decoration may include, but is not limited to, a decoration 30C including the number "92" with the decoration 30C in a predetermined alignment relative to the first decoration 23B. Those skilled in the art will appreciate that first decor 23 and decor 30 formed by decorator 2 can have any relative size and arrangement with respect to each other.

Optionally, the upstream apparatus 26 may include a surface treatment unit 27. The surface treatment unit 27 may prepare the outer surface portion 24 of the metal container 22 to receive the decoration 7 from the transfer blanket 6. In one embodiment, the surface treatment unit 27 treats the exterior surface portion 24 by one or more of plasma treatment, anodizing treatment, applying a primer coating material, and applying a pre-coating. In one embodiment, the plasma treatment comprises a corona surface treatment or an air plasma treatment that uses a low temperature corona discharge plasma to modify the surface characteristics of the metal container 22. In another embodiment, the exterior surface 24 of the metal container 22 may be pretreated by one or more of corona surface treatment, flame plasma treatment, chemical plasma treatment, electroplating, electrostatic plating, chemical coating, anodizing, thermal dipping, and thermal spraying. The pre-treatment generally improves the adhesion and bonding between the decoration 7 applied by the decorator 2 and the outer surface 24 of the metal container 22.

The decorated metal containers 28 may be conveyed from the feeding unit 8 to the downstream apparatus 32 by means of the conveyor belt 13 or the like. Any suitable conveyor belt 13 may be used in conjunction with decorator 2 of the present invention. The conveyor belt 13 may be the same as or similar to the conveyor belt 10. In one embodiment, one or more of the

conveyor belts

10, 13 comprises a belt or chain. In one embodiment, the conveyor belt 13 is a pin chain. Suitable pin chains are known to those skilled in the art and include the pin chain described in U.S. patent application publication 2017/0334659, the contents of which are incorporated herein by reference in their entirety.

Optionally, in one embodiment of the invention, the conveyor belt 13 conveys the decorated metal containers 28 to the curing unit 17. The curing unit 17 may be the same as or similar to the curing unit 16. Accordingly, the curing unit 17 is operable to at least partially cure the trim material forming the trim 30 on the container exterior surface 24. The curing unit 17 may cure or solidify the decorating material using at least one of thermal energy and light of a predetermined wavelength. In one embodiment, the curing unit 17 comprises an ultraviolet or ultraviolet LED curing lamp. In another embodiment, the curing unit 17 is operable to cure or solidify the trim material using thermal energy. The curing unit 17 may be used in conjunction with the curing unit 16 or in place of the curing unit 16. More specifically, in one embodiment, the decorator includes only one of the curing unit 16 and the curing unit 17. Curing unit 17 is operable to cure one or more of the ink and toner on metal container 28.

In one embodiment, the downstream equipment 32 includes one or more of a coater, an oven, a waxing machine, a neck molding machine, a tester, an inspection station, and a stacker. The coater may apply paint (or other material, such as varnish) to the interior surface of the metal container 28. The oven cures the paint. The waxing machine may apply a thin layer of lubricant to the portion of the container body near the open end of the metal container 28. The neck molding machine reduces the diameter of a portion of the metal container body and applies a bead to the aerosol container. The tester checks the container for an accidental seam or leak. The inspection station may inspect the shape or other characteristics of the metal container 28. The stacker can bundle the finished metal containers 28 for shipment or storage.

An example of a decorated

metal container

28A, 28B is also shown in fig. 1. The

metal containers

28A, 28B include

unique decorations

30A, 30B, 30C, respectively, on the outer surface portion 24. In addition, the decoration 30 may be in a predetermined alignment with respect to the first decoration 23 applied by the upstream apparatus 26. It should be understood that the decoration 30 may be formed anywhere on the outer surface portion 24 of the metal container 28. Further, the decorations 30 may include text, customer identification information, brand information, instructions for use, or any other desired decoration or indicia.

In addition, as described above, decorator 2 may be used to decorate end cap 34, ROPP closure, and crown cap 36. Also shown in fig. 1 is an example of an end cap 34 and crown cap 36 with a decor 30 formed by the decorator 2 of the present invention.

Alternatively, two or more feed units 8 may be associated with decorator 2A. More specifically, referring now to fig. 1C, in one embodiment of the present invention, decorator 2A includes at least two

feed units

8A, 8B. The decorator 2A includes a plurality of transfer blanket sections 6A. The felt sections 6A are arranged in sequence on a felt wheel 18. The

feed units

8A, 8B are aligned relative to the blanket wheel 18 so that the feed unit 8A picks up every other decoration 7 formed on the transfer blanket section 6A. More specifically, the feeding unit 8A moves the metal container 22 so as to be in contact with every other transfer blanket section 6A at the first image transfer position 25A. The second feeding unit 8B moves the metal container 22 into contact with the alternate transfer blanket sections 6A at the second image transfer position 25B. In this manner, decorator 2A may operate at a different rate than the container production process. Alternatively or additionally, the blanket wheel 18 can rotate at a faster speed than the decorator 2 having only one feed unit. Since decorator 2A includes two

feed units

8A, 8B, although felt wheel 18 rotates faster, the circulation rate of

feed units

8A, 8B may be the same or similar to the circulation rate of feed unit 8 of the decorator shown in fig. 1. In this manner, the decorator 2A shown in fig. 1C can decorate more containers per hour than the decorator shown in fig. 1.

Referring now to FIG. 3, another embodiment of the present invention, a decorator 2B is generally shown. Decorator 2B includes a digital print unit 4, one or more curing units 16, a feed unit 8A, and an optional curing unit 17, which are the same or similar to the components of decorator 2A. Decorator 2B also includes a continuous transfer blanket 6B. Specifically, the transfer blanket 6B is at least one loop of blanket material. The digital printing unit 4 can include an inkjet printhead 41, the inkjet printhead 41 operable to transfer ink 43 onto the transfer blanket 6B, as shown in fig. 2A. Alternatively, at least one of the digital printing units 4 may be an electrophotographic system 40, as generally shown and described in connection with fig. 2B. The relative position and order of the digital printing units 4 may vary.

Decorator 2B can include at least one temperature control device 5A configured to heat or cool transfer felt 6B. The temperature control device 5A may be positioned in contact with the outer surface of the transfer blanket 6B. Alternatively or additionally, decorator 2B can include a temperature control device 5A positioned in contact with the inner surface of transfer blanket 6B. In another embodiment, the temperature control device 5A is operable to change the temperature of the transfer blanket 6B by not being in contact with the transfer blanket.

In one embodiment, the width 65 (as shown in FIG. 5) of the transfer blanket 6B is not less than the height of the metal container 22 to be decorated. Alternatively, the width 65 of the mat may be greater than the container height. In one embodiment, the transfer blanket 6B is formed of the same or similar material as the transfer blanket section 6A. The transfer blanket 6B may have any desired length. In one embodiment, the length of the transfer blanket 6B is between about 5 meters and about 20 meters. In another embodiment, the length of the transfer blanket 6B is at most about 50 meters.

The transfer blanket 6B may be tensioned to prevent accidental or accidental movement. More specifically, in one embodiment, decorator 2B is operable to maintain transfer blanket 6B at a sufficient tension that is sufficient to counteract the force received from metal container 22 that is in contact with transfer blanket 6B to receive decoration 7.

In one embodiment, decorator 2B includes one or more tensioning devices 54-62. These tensioners may be selectively in contact with the transfer blanket 6B. In this manner, in one embodiment, the tensioning devices 54-62 may vary the tension of the transfer blanket 6B. In one embodiment, the tensioning device of decorator 2B includes at least one of an inboard idler 54, a rear idler 56, a shoe tensioning device 58, a rotary tensioning device 60, and a platen roller 62. In one embodiment, the surface of the shoe tensioner 58 configured to contact the transfer blanket 6B has a generally arcuate shape. The shoe tensioner 58 may be of any size. Other arrangements and locations of the tensioning devices 54-62 are contemplated.

In one embodiment of the invention, decorator 2B includes an impression roller 62 near image transfer position 25. Optionally, a rear idler pulley 56 is provided after one or more of the servo drive 64 and the image transfer station 25. The inboard idler pulley 54 may be provided before the servo drive 64. A second inside idler 54 may be provided after the image transfer station 25. Alternatively, a two-roller tensioning device 60A may be provided after the image transfer position 25. A shoe tensioner 58 may also be provided after the image transfer station 25 and before the first digital print unit 4.

Optionally, one or more of the tensioners (e.g., inboard idler 54, rear idler 56, shoe tensioner 58, rotary tensioner 60, and impression roller 62) may be interconnected with an actuator. More specifically, the tensioning devices 54-62 may be adjustably disposed relative to the transfer blanket 6B. In this manner, one or more of the tensioning devices 54-62 may be moved relative to the transfer blanket 6B. In another embodiment, the control system 12 may send signals to one or more actuators associated with the tensioners 54-62. These signals may cause the actuator to move the associated tensioner 54-62 in a particular direction or in a particular manner. For example, referring to FIG. 3A, a signal from the control system 12 may cause an actuator associated with the inner idler 54 to press against the inner surface of the transfer felt 6B. In this way, the inner idle roller 54 can change the tension of the transfer blanket 6B. Similarly, referring now to fig. 3B, control system 12 may send a signal to the actuator of rear idler 56 to move rear idler 56 inward relative to transfer felt 6B to change the tension of the transfer felt. Alternatively, the actuator drive 64 may have a complementary actuator. Accordingly, the control system 12 can send a signal to the actuator to move the servo drive 64 to increase or decrease the tension of the transfer blanket 6B. By changing the position of the servo drive 64 using an actuator, the tension of the transfer blanket can be advantageously adjusted without adding a deflection point to the transfer blanket.

Referring now to fig. 3C, shoe tensioner 58 is shown in an engaged position in contact with the outer surface of transfer felt 6B. More specifically, the shoe tensioner 58 is shown generally in a position adjusted by the actuator. In this manner, shoe tensioner 58 may move relative to transfer felt 6B in response to signals received from control system 12. FIG. 3C also shows a shoe tensioner 58, the surface of the shoe tensioner 58 having a generally arcuate shape that contacts the transfer blanket. The shoe tensioner can have any predetermined size. Further, the radius of curvature of the arcuate surface may be any predetermined dimension.

By selectively arranging the tensioners 54-62 and optionally the servo drive 64 around the inner and outer surfaces of the transfer blanket 6B, the tension of the transfer blanket 6B can be adjusted to a substantially constant value. Further, the arrangement of the tensioners 54-62 and/or the servo drive 64 may be selected to prevent or reduce vibration of the transfer blanket 6B. In addition, the combination of the tensioning devices 54-62 or the servo drive 64 may eliminate or reduce warping or other unintended movement of the transfer blanket. Thus, adjusting the tension of the transfer blanket 6B with the tensioning devices 54-62 and/or the servo drive 64 can improve the quality of the decoration 30 formed on the metal container 28 and extend the life of the transfer blanket.

In one embodiment, one or more of the

tensioning devices

54, 56, 60, 62 may be selectively actuated to effect rotation of the transfer blanket 6B. In another embodiment, the

tensioners

54, 56, 60, 62 may be idle.

In one embodiment, rotary tensioning device 60 includes two or more rollers 61 as a two-roller rotary tensioning device 60A, as shown in fig. 3D. More specifically, the rotary tensioner 60A of one embodiment of the present invention may include a first roller 61A configured to contact a first side of the transfer blanket 6B. The second roller 61B may be configured to contact the second side of the transfer blanket 6B. The

rollers

61A, 61B are interconnected by a link 63. Alternatively, the

rollers

61A, 61B may have the same or different diameters. In one embodiment, rotary tensioning device 60A may be used in conjunction with decorator 2B in addition to or in place of rotary tensioning device 60.

Alternatively, decorator 2B includes an impression roller 62. In one embodiment, the impression roller 62 applies a force to the transfer blanket 6B during transfer of the decoration 7 to the metal container 22. In another embodiment, during transfer of decoration to a metal container, the impression roller 62 applies a force to a transfer felt surface substantially opposite the outer surface of the transfer felt 6B that contacts the metal container 22.

In one embodiment, the force applied by the impression roller 62 to the transfer blanket 6B during transfer of the decoration 7 to the metal container is substantially equal to the force applied by the metal container 22 to the transfer blanket. In this manner, embossing roll 62 eliminates or minimizes the dynamic effects on transfer blanket 6B. The balancing force applied to the transfer blanket by the impression roller 62 and the metal reservoir 22 also minimizes wear of the transfer blanket. Thus, decorator 2 can be operated for a longer period of time without service than a similar decorator that cannot balance the forces received from the metal container.

In one embodiment, decorator 2 may include a plurality of

embossing rollers

62A, 62B, 62C. The impression roller 62 may be oriented to vary the tension of the transfer blanket 6B near the feed unit 8. For example, decorator 2B may include two or more nip rollers 62 such that the tension of transfer blanket 6B at transfer location 25 near feed unit 8A is different than the tension of other portions of transfer blanket 6B. Isolating the transfer blanket tension near the point of contact between the transfer blanket and the metal container minimizes or eliminates accidental and incidental movement of the transfer blanket 6B during contact of the transfer blanket 6B with the metal container 22 during the process of picking up the decoration. Therefore, when the digital printing unit 4 conveys the finishing material to the transfer blanket 6B, the force received from the metal container 22 does not cause the unintended movement of the transfer blanket 6B. This improves the quality of the decoration.

In one embodiment, the decorator 2B includes a first impression roller 62A located upstream of the image transfer position 25 where the decor material 7 is transferred from the transfer blanket 6B to the metal container 22. Alternatively, a second platen roller 62B may be disposed substantially at the image transfer position 25. In one embodiment, a third impression roller 62C is arranged downstream of the transfer position 25.

In one embodiment, decorator 2B includes at least one servo drive 64 that rotates transfer blanket 6B at a predetermined rate. The servo drive device 64 is configured to apply a force to the transfer blanket 6B so that the transfer blanket 6B rotates at a predetermined rate. In one embodiment of the present invention, the servo drive device 64 is configured to pull the transfer blanket 6B. Alternatively or additionally, the servo drive 64 may be configured to push the transfer blanket 6B. Alternatively, the first servo drive 64 may be configured to push the transfer blanket 6B, and the second servo drive 64 may be configured to pull the transfer blanket 6B.

The servo drive device 64 can rotate the transfer blanket 6B substantially continuously. Alternatively, the servo drive device 64 may change the rotation speed of the transfer blanket 6B. For example, in one embodiment of the present invention, the servo drive 64 reduces the rotational speed. The reduced rotational speed may be coordinated with one or more operations of decorator 2B. More specifically, in one embodiment, the servo drive 64 reduces the rotational speed during curing of the decor 7 by the one or more curing units 16. In another embodiment, servo drive 64 increases the rotational speed of transfer blanket 6B during other operations of decorator 2B. Therefore, in another embodiment, the servo drive device 64 increases the rotation speed during one or more of the operation of transferring the finishing material to the transfer blanket 6B and the operation of transferring the decoration 7 to the metal container 22 by the digital printing unit 4.

In another embodiment, servo drive 64 intermittently rotates transfer blanket 6B. More specifically, the servo drive device 64 may periodically start and stop the rotation of the transfer blanket 6B. In this manner, the transfer blanket 6B may be periodically stopped during formation of the decoration 7 by the digital printing unit 4, during curing of the decoration material by the curing unit 16, and/or during transfer of the decoration 7 to the metal container 22. In this manner, the transfer blanket 6B may be in a fixed orientation relative to the metal container 22 during the transfer of the decoration 7 to the metal container 22.

In one embodiment, the servo drive 64 is a load balancing servo drive. The load-leveling servo drive device 64 can adjust the force applied to the transfer blanket 6B so that the rotation speed of the transfer blanket 6B is kept substantially constant. More specifically, the load-leveling servo drive 64 may apply a greater or lesser force to maintain the rotational speed of the transfer blanket substantially constant. In one embodiment, the load-leveling servo drive 64 is configured to adjust the force applied to the transfer blanket 6B such that the tension in the blanket 6B is substantially constant. In this manner, the load-leveling servo drive 64 can maintain a constant tension in the transfer blanket 6B at one or more positions. In one embodiment, load-leveling servo drive 64 may adjust the force applied to transfer blanket 6B such that the tension at one or more image transfer locations 25 and the print zone adjacent one or more digital print units 4A-4D is substantially constant. By maintaining the tension of the transfer blanket substantially constant, the load-leveling servo drive 64 can reduce "noise" or vibration of the transfer blanket 6B. This can improve the quality of the decoration formed by the digital printing unit 4 and reduce distortions or other errors that occur during the transfer of the decoration to the metal container 22 at the transfer position 25.

In another embodiment, during the transfer of the decoration 7 to the metal container, the servo drive 64 is operable to adjust the rotational speed of the transfer blanket 6B to substantially match the rotational speed of the cylindrical outer surface 24 of the metal container 22. In one embodiment, control system 12 is operable to vary the rotational speed of servo drive 64 to adjust the rotational speed of transfer blanket 6B. More specifically, the control system 12 may send a signal to the servo drive 64 to set the rotational speed of the transfer blanket 6B.

In one embodiment, the feed unit 8A is operable to rotate the metal container 22 such that the outer surface 24 moves at a rate substantially equal to the rotational speed of the transfer blanket 6B. In one embodiment, the surface speed of the rotating container 22 is substantially equal to the rotational speed of the embossing roller 62. In this way, the dynamic influence on the transfer blanket 6B can be minimized. Alternatively, the feeding unit 8A may include a spindle 11 for supporting the metal container 22, similar to the feeding unit 8A described in connection with fig. 1. The mandrel 11 can rotate the metal container 22 in a state of being in contact with the transfer blanket 6B at the image transfer position 25. In one embodiment, the mandrel 11 rotates at a rate substantially equal to the rotational speed of the transfer blanket 6B. In another embodiment, the control system 12 may send a signal to the spindle 11 to control the rotation of the spindle. In one embodiment, the spindle 11 may be rotated using a servo drive or other electrical or mechanical device. Optionally, the mandrel 11 is the same as or similar to the mandrel of decorator 2A. Thus, the spindle 11 may rotate in response to a force received from a belt or chain interconnected with the drive unit 64.

The feeding unit 8A may be disposed at different positions with respect to the transfer blanket 6B. For example, in one embodiment, the feeding unit 8A is arranged such that the metal container 22 can be transferred to the feeding unit 8A under the action of gravity. Thus, in one embodiment, the feed unit 8A is disposed adjacent to one of the rotary tensioner 60 and the servo drive 64. Alternatively, in another embodiment, the feeding unit 8A is arranged near the curing unit 16D.

In one embodiment of the invention, the transfer blanket 6B may rotate at a speed of about 150 meters/minute to about 250 meters/minute. While transfer blanket 6B is rotating at a speed of about 200 meters per minute, decorator 2B can decorate about 700 to about 900 metal containers per minute. In another embodiment, the decorator decorates about 725 to about 775 metal containers per minute at a rotational speed of about 200 meters per minute.

Referring now to fig. 3E, decorator 2B may optionally include two feed units 8. The feeding unit 8 may be arranged with respect to the transfer blanket 6B to provide two image transfer positions 25A, 25B. More specifically, the first feeding unit 8A may be arranged upstream of the second feeding unit 8B with respect to the transfer blanket 6B. In this way, the first and second feeding units 8 can decorate the metal containers 22 sequentially from one or more production lines. In addition, each

feed unit

8A, 8B may have an associated

independent conveyor belt

13A, 13B. Thus, metal containers from two separate production lines may optionally be decorated by the decorating machine 2B and subsequently separated by the

conveyor belts

13A, 13B for subsequent processing without having to mix the metal containers together. In one embodiment, the first feeding unit 8A moves the metal container 22 into contact with every other decoration 7 on the transfer blanket 6B. For example, the decoration 7A is transferred onto a metal container 22 arranged on the mandrel 11 of the feeding unit 8A. However, the

decorations

7B, 7D pass through the feeding unit 8A and are transferred onto the metal container 22 moved to a state of contact with the transfer blanket 6B by the second feeding unit 8B. As shown in fig. 3E, a blank area on the transfer blanket 6B separates the decoration 7B from the decoration 7D. This blank area represents the location of the transfer blanket 6B previously with the decoration that has been transferred onto the metal container supported by the first feeding unit 8A. Alternatively, the feeding unit 8A may rotate in a first direction, while the feeding unit 8B may rotate in an opposite second direction.

Referring now to fig. 4, there is shown another embodiment of the decorator 2C of the present invention. Decorator 2C, similar to decorator 2B, also includes a single continuous transfer blanket 6C as well as a digital print unit 4 and a feed unit 8. The transfer blanket 6C may be the same as or similar to the transfer blanket 6B of the decorator 2B. Note that the transfer blanket 6C has a different path compared to the transfer blanket 6B. More specifically, transfer blanket 6C travels along an irregular path about the plurality of tensioning units 54-62 and servo drive 64 relative to digital print unit 4 and curing unit 16.

In one embodiment, the feeding unit 8C includes a plurality of spindles 11 for placing the metal container 22 in a position to contact the transfer blanket 6. The spindle 11 is optionally rotatable in one or more directions. In one embodiment, the spindle 11 has a complementary servo drive. In one embodiment, each spindle has an associated servo drive. The servo drive selectively rotates the mating spindle. In another embodiment, the servo drive is controlled by signals from the control system 12. More specifically, the control system 12 may send a signal to the servo drive to rotate the spindle 11 in a particular direction at a particular rate. Alternatively, in another embodiment, mechanical or electrical means may be used to rotate the spindle 11. In another embodiment, the spindle 11 has a matching torque motor. Examples of mandrels that may be used in conjunction with the feed unit 8 of the present invention are illustrated in U.S. patent 8,596,624 and U.S. patent 8,708,271, the contents of which are incorporated herein by reference in their entirety.

In one embodiment, decorator 2C includes one or more tensioning devices 54-62, similar to decorator 2B. The tensioning devices may be arranged at different positions with respect to the transfer blanket 6C. In one embodiment, decorator 2C includes at least one of an inboard idler 54, a rear idler 56, a shoe tensioner 58, a rotary tensioner 60, and a nip roller 62. Alternatively, the order, arrangement, and number of the tensioners 54-62 may be varied. For example, in one embodiment, decorator 2C can include one embossing roll 62. In another embodiment, decorator 2C includes three embossing rollers 62. Alternatively, the first impression roller 62A may be located upstream of the decoration transfer position 25. In another embodiment, the impression roller 62B is located near the transfer position 25. In addition, an optional impression roller 62C may be disposed downstream of the transfer position 25.

The

tensioners

54, 56, 60, and 62 may be idle. Alternatively or additionally, at least one of the

tensioners

54, 56, 60, and 62 may be mated to a servo drive to provide a rotational force to the transfer blanket 6C. In one embodiment, one or more of the tensioning devices 54-62 and the servo drive 64 are movably disposed relative to the transfer felt 6C. Accordingly, the tensioners 54-62 and/or the servo drive 64 can be moved into and out of contact with the transfer blanket 6C. In one embodiment, the control system 12 may send signals to actuators associated with the tensioners 54-62 or the servo drive 64 to change the position of the tensioners or the servo drives. In this manner, the control system 12 can adjust the tension of the transfer blanket 6C.

Decorator 2C may also include at least one servo drive 64. The servo drive 64 may be the same as or similar to the servo drive 64 of decorator 2B. Thus, the servo drive 64 may rotate substantially continuously. In another embodiment, the servo drive device 64 is intermittently rotated so that the transfer blanket 6C is alternately in the moving period and the stationary period. In one embodiment, the servo drive 64 is controlled by the control system 12. More specifically, control system 12 may send signals to servo drive 64 to change the rotational speed of the servo drive, start the rotation of the servo drive, and stop the servo drive.

Alternatively, decorator 2C can include at least one temperature control device 5A configured to heat or cool transfer blanket 6C to a predetermined temperature. The temperature control device 5A may be disposed in contact with the outer surface or the inner surface of the transfer blanket 6C. Alternatively, the temperature control device 5A is configured to change the temperature of the transfer blanket 6C in a non-contact manner.

Referring now to FIG. 5, in one embodiment, the transfer blanket 6 may include at least two sections 66. More specifically, in one embodiment, the transfer felt 6C includes multiple sections 66A-66D. In one embodiment, each segment 66 is substantially parallel to one or more adjacent segments. Alternatively, each segment 66 may have substantially the same size and shape. In another embodiment, each segment 66 is formed of the same material. In another embodiment, at least one segment 66A comprises a different material than the other segments 66B-66D.

Optionally, segment 66B may be interconnected with at least one

adjacent segment

66A, 66C along longitudinal edge 67. In another embodiment, the individual segments 66 are interconnected along longitudinal edges 67 at least near the transfer location 25 when transferring the trim material to the metal container 22.

The transfer blanket 6C has a width 65. In one embodiment, the width 65 may be at least equal to the height of the metal container 22 to be decorated. In one embodiment, the width 65 is greater than the container height.

In one embodiment, the individual segments 66 are not interconnected. Thus, in one embodiment, the tension of each segment 66 may be independently adjusted. For example, in one embodiment, one or more of the tensioning devices 54-62 may selectively adjust the tension of one or more of the strands 66.

In another embodiment, each segment 66 has at least one associated servo drive 64. In this manner, the rotational speed of each segment 66 may be selectively adjusted relative to the other segments. Further, while one segment 66A is stopped, the other segments 66B-66D may continue to rotate. Although only four segments 66A-66D are shown in FIG. 5, one skilled in the art will appreciate that the transfer blanket 6C may include any number of segments 66. Alternatively, the transfer felt 6C may be formed of 2 to 8 segments 66.

In another embodiment, at least one segment 66A may follow a different path through decorator 2C than one or more of segments 66B-66D. In this manner, at least one segment 66 may bypass one or more of digital printing units 4. Alternatively, at least one segment 66 may have a different length than another segment 66. Alternatively, at least one segment 66 may receive trim material from a digital printing unit 4 that does not transfer trim material to one or more of the other segments 66.

The segments 66 of transfer felt 6C provide a number of benefits. In one embodiment, more metal containers 22 may be decorated with a transfer blanket 6 comprising segments 66. More specifically, the rotational speed of the transfer blanket 6 is typically limited by the maximum speed at which the digital print unit 4 can transfer the trim material to the transfer blanket. The parallel felt sections 66 multiply the output of the same basic metal container handling unit, e.g. the feed unit 8. In addition, the felt segments 66 provide redundancy. This ensures stable output of the decorated metal container from the decorating machine. More specifically, in one embodiment, each segment 66 may be independently operable. Thus, while one segment 66 stops, the other segments may continue to rotate relative to the digital printing unit. In addition, the individual felt sections 66 may isolate the transfer felt from noise generated during transfer of the image to the metal container. For example, if each felt section 66 has an associated independent feed unit 8 (e.g., as described in connection with FIG. 5A), then the vibration and noise generated in the transfer felt 6C during image transfer may be reduced. By separating the time when the decoration is transferred from the first section 66A to one metal container from the time when the decoration is transferred from the second section 66B to another metal container, the noise in the transfer blanket 6C can be further reduced. The separate felt sections 66 also allow for different operating temperatures of the sections. This can further reduce the wear and deterioration of the transfer blanket 6C.

In another embodiment, each section 66 of the transfer felt 6 of the decorator 2 can have a complementary feed unit 8. More specifically, referring now to fig. 5A, a partial cross-sectional view of a decorator 2D of another embodiment of the present invention is generally shown. Decorator 2D is similar to

decorators

2B, 2C and generally includes digital print unit 4, cleaning system 14, curing units 16, 17, tensioning devices 54-60, and servo drive 64 (not shown for clarity). Notably, the decorator 2D includes a continuous transfer blanket 6D that includes two

segments

66A, 66B that are aligned relative to the two feed units 8 at the

image transfer locations

25A, 25B. The impression roller 62 is arranged to support the transfer blanket 6D during contact of the transfer blanket 6D with the metal container. Alternatively, two

separate embossing rollers

62A, 62B are provided so that each felt section 66 can have one

mating embossing roller

62A, 62B. In this manner, the digital printing unit 4 can transfer the upholstery material (e.g., ink or toner) to the transfer felt 6D to form the image 7. The first section 66A of the transfer blanket 6D may then transfer the image 7A to the first metal container 22A. The second segment 66B may similarly transfer the second image 7B to the second metal container 22B. Alternatively,

segments

66A, 66B may rotate through decorator 2D at the same or different rates. In one embodiment, decorator 2D can decorate about 1400 to 1600 containers per minute while transfer blanket 6D is rotating at a rate of about 200 meters per minute.

Additionally, in one embodiment, the first metal container 22A may be configured with a first manufacturing line and the second metal container 22B may be configured with a second manufacturing line. More specifically, the first metal container 22A may have a different size, shape, or material than the second metal container 22B. Thus, in one embodiment of the present invention, decorator 2 of the present invention may be integrated into two different container lines.

FIG. 5A also shows a mandrel 11A of one embodiment of the present invention. Alternatively, the mandrel 11A may move relative to the transfer blanket 6D. More specifically, in one embodiment, the spindle 11A is movably interconnected with the feed unit 8. Alternatively, the spindle 11A may have a mating actuator. In this manner, the mandrel can selectively move the metal reservoir 22 thereon into and out of contact with the transfer blanket.

Although transfer blanket 6D is shown with two segments 66 aligned with two feed units 8, any number of segments 66 and feed units 8 may be used in conjunction with decorator 2 of the present invention. More specifically, in another embodiment, the transfer blanket 6C shown in fig. 5 may be configured with four feeding units 8. In one embodiment, the decorator 2, which includes four feed units 8 associated with four segments 66 of transfer blanket 6, can decorate about 1850 to about 2100 containers per minute while the transfer blanket 6 is rotating at a speed of about 200 meters per minute.

Referring now to FIG. 6, a control system 12 of one embodiment of the present invention is generally shown. The control system 12 is generally shown as having hardware elements that may be electrically coupled via a bus 68. The hardware elements may include one or more Central Processing Units (CPUs) 70; one or more input devices 72 (e.g., a mouse, keyboard, etc.); and one or more output devices 74 (e.g., a display, a printer, etc.). The control system 12 may also include one or more memory devices 76. In one embodiment, the storage 76 may be a disk drive, an optical storage, a solid state storage (e.g., random access memory ("RAM") and/or read only memory ("ROM"), which may be programmable, flash updateable, or the like.

The control system 12 may also include one or more of a computer-readable storage media reader 78, a communication system 80 (e.g., a modem, a network card (wireless or wired), an infrared communication device, etc.), and a working memory 82 (which may include the RAM and ROM described above). In some embodiments, the control system 12 may also include a processing acceleration unit 84, and the processing acceleration unit 84 may include a Digital Signal Processor (DSP), a special purpose processor, or the like. Optionally, the control system 12 also includes a database 86. The database may include information relating to the decoration 23 applied to the metal container 22 by the upstream equipment 26. Alternatively or additionally, the database 86 may include information describing the decor 7 to be formed by the decorator 2 of the present invention.

The computer-readable storage media reader 78 may also be connected to computer-readable storage media that collectively (and optionally in conjunction with the storage device 76) collectively represent remote, local, fixed, and/or removable storage devices as well as storage media for temporarily and/or more permanently containing computer-readable information. Communication system 80 may allow data to be exchanged with network 88 and/or any other data processing device. Alternatively, the control system 12 may access data stored in a remote storage device, such as a database 90, by connecting to the network 88. In one embodiment, the network 88 may be the Internet.

The control system 12 may also include software elements, shown here as being located within the working memory 82. The software elements may include an operating system 92 and/or other code 94, such as program code implementing one or more methods and aspects of the present invention. In one embodiment, instructions for sending signals to the digital printing unit 4 to form the decoration 7 are stored in the working memory 82. In another embodiment, working memory 82 contains instructions related to the signals to be sent to exposure element 46 to form decoration 7 on conductor 42. Alternatively, the working memory 82 may contain instructions relating to aspects of one or more of the decorator 2, the digital printing unit 4, the feed unit 8, the mandrel 11, the cleaning system 14, the curing units 16, 17, the blanket wheel 18, the upstream apparatus 26, the surface treatment unit 27, the downstream apparatus 32, the electrophotographic system 40, actuators associated with the tensioning devices 54-62 of the

decorators

2B, 2C, the servo drive 64, and the impression roller 62. Thus, in one embodiment, the control system 12 may send signals to one or more of the digital print unit 4, the feed unit 8, the mandrel 11, the curing units 16, 17, and the blanket wheel 18, as well as the servo drive 64, to synchronize the operation of the decorator 2. In this manner, the control system 12 can send a signal to the digital printing unit 4 for forming the decoration 7 on the transfer blanket 6, so that the decoration 7 is aligned with the metal container 22 on the feeding unit 8.

Those skilled in the art will appreciate that alternative embodiments of control system 12 may have variations other than those described above. For example, customized hardware might also be used and/or particular elements might be implemented in hardware, software (including portable software, such as applets), or both. Further, connections to other computing devices (e.g., network input/output devices) may be employed.

The control system 12 may be in communication with one or more of the decorator 2, the digital print unit 4, the feed unit 8, the inbound web 10, the outbound web 13, the cleaning system 14, the optional curing units 16, 17, the felt wheel 18, the tensioning devices 54-62, and the servo drive 64. The control system 12 can send signals to the digital printing unit 4 to adjust the position of the decoration 7 formed on the transfer blanket 6. In one embodiment, the control system 12 is further operable to provide a unique signal to each digital print unit 4 to form a unique decoration 7 on each transfer blanket 6. Thus, the control system 12 can send the digital printing unit 4 the unique design of each decor 7.

Suitable control systems 12 are well known to those skilled in the art. In one embodiment, the control system 12 is a personal computer, such as, but not limited to, a personal computer running the Microsoft Windows operating system. Alternatively, the control system 12 may be a tablet computer, laptop computer, and similar computing device. In one embodiment, the control system 12 is a data processing system including, but not limited to, one or more of the following: at least one input device (e.g., a keyboard, mouse, or touch screen); at least one output device (e.g., a display); a graphics card; a communication device (e.g., an ethernet card or a wireless communication device); persistent storage (e.g., hard drives); temporary memory (e.g., random access memory); and a processor. The control system 12 may be any Programmable Logic Controller (PLC). One example of a suitable PLC is the Controllogix PLC manufactured by Rockwell Automation, inc, although other PLCs are contemplated for use in connection with embodiments of the present invention.

The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments described herein and illustrated in the drawings were chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention.

Although various embodiments of the present invention have been described in detail hereinabove, it is apparent that those skilled in the art can make various modifications and variations thereto. Moreover, references herein to "the invention" or aspects thereof should be understood to refer to particular embodiments of the invention, and not to limit all embodiments to the particular descriptions herein. It is to be expressly understood that such modifications and variations are within the scope and spirit of the present invention as defined by the following claims.

Claims

1. An apparatus for decorating the exterior surface of a metal container, comprising:

a first transfer blanket section;

a second transfer blanket section;

a digital printing unit in a predetermined alignment with respect to the first and second transfer blanket sections, the digital printing unit operable to convey the trim material to the first and second transfer blanket sections to form a first trim on the first transfer blanket section and a second trim on the second transfer blanket section, wherein the digital printing unit comprises one of an electrophotographic system and an inkjet print head;

a first feed unit for moving the first metal container into contact with the first transfer blanket section to transfer the first decoration from the first transfer blanket section onto the outer surface of the first metal container, wherein the first transfer blanket section is spaced a first distance from the second transfer blanket section when the first transfer blanket section is positioned adjacent the digital printing unit, and wherein the first transfer blanket section is spaced a second distance from the second transfer blanket section when the first transfer blanket section is positioned adjacent the first feed unit, the first distance being different from the second distance; and

a cleaning system downstream of the first feed unit to remove residual trim material from the first and second transfer blanket sections, wherein the first transfer blanket section is spaced from the second transfer blanket section by a third distance different from the second distance when the first transfer blanket section is positioned adjacent the cleaning system.

2. The apparatus of claim 1, wherein the decorating material comprises at least one of an ink and a toner material.

3. The apparatus of claim 1, wherein the first transfer blanket section moves at a first speed adjacent the digital print unit and the second transfer blanket section moves at a second speed adjacent the first feed unit, the first speed being slower than the second speed.

4. The apparatus of claim 1, wherein the first distance is less than the second distance.

5. The apparatus of claim 1, wherein the first and second transfer blanket sections are configured to move at a first speed adjacent the digital print unit and the first and second transfer blanket sections are configured to move at a second speed adjacent the first feed unit.

6. The apparatus of claim 5, wherein the first speed is slower than the second speed.

7. The apparatus of claim 5, wherein the first transfer blanket section has a leading end and a trailing end and the second transfer blanket section has a leading end and a trailing end, and wherein a distance between the leading end of the first transfer blanket section and the leading end of the second transfer blanket section changes as the first transfer blanket section changes from the first speed to the second speed.

8. The apparatus of claim 1, further comprising one or more of:

a curing unit downstream of the digital printing unit and upstream of the first feeding unit, the curing unit being configured to at least partially cure the trim material delivered to the first and second transfer blanket sections;

a temperature control device operable to adjust a temperature of the first transfer felt section; and

one or more of a thermal system and a uv system configured to adjust the viscosity of the ink delivered by the inkjet print head onto the first and second transfer blanket sections.

9. The apparatus of claim 1, wherein the electrophotographic system comprises a conductor, a charging element, an exposure element, and a developing unit that provides a finishing material, wherein the finishing material is a toner material.

10. The apparatus of claim 1, wherein the first feed unit is aligned with a first image transfer location of the apparatus and includes a plurality of first mandrels to receive the metal containers, wherein the apparatus further includes a second feed unit having a plurality of second mandrels to receive the metal containers, the second feed unit being aligned with a second image transfer location of the apparatus, the second feed unit being spaced apart from the first feed unit and the first image transfer location, the second feed unit being configured to move the second metal container into contact with and support the second metal container during transfer of the second decoration to an outer surface of the second metal container.

11. A method of forming a decoration on an outer surface portion of a cylindrical container, comprising:

transferring the trim material from a digital printing unit to a first transfer blanket section of a decorator such that the trim material forms a first decor on the first transfer blanket section, the digital printing unit including at least one of an inkjet printhead and an electrophotographic system, and the trim material including at least one of an ink and a toner material, wherein the first transfer blanket section is spaced a first distance from a second transfer blanket section when the first transfer blanket section is positioned adjacent the digital printing unit;

providing a first cylindrical container;

placing the first cylindrical container in a first feed unit of a decorator;

changing a distance between a first transfer blanket section and a second transfer blanket section as the first and second transfer blanket sections move from the digital printing unit to the first feed unit, wherein the first transfer blanket section is spaced from the second transfer blanket section by a second distance when the first transfer blanket section is positioned adjacent the first feed unit, the first distance being different than the second distance;

moving an outer surface portion of the first cylindrical container into contact with the first transfer felt section, wherein the first decoration is transferred from the first transfer felt section onto the outer surface portion of the first cylindrical container; and

changing a distance between the first transfer blanket section and the second transfer blanket section as the first and second transfer blanket sections move away from the first feed unit, wherein the first transfer blanket section is spaced apart from the second transfer blanket section by a third distance when the first transfer blanket section is positioned adjacent to a cleaning system of the decorator, the third distance being different from the second distance.

12. The method of claim 11, wherein the second distance is greater than the first distance, and wherein a first transfer blanket section is adjacent to the second transfer blanket section.

13. The method of claim 11, further comprising:

transferring additional trim material from the digital printing unit to the second transfer blanket section to form a second trim on the second transfer blanket section;

providing a second cylindrical container;

placing a second cylindrical container in a second feed unit of the decorator, wherein the first feed unit is aligned with a first image transfer location of the decorator and includes a plurality of first mandrels to receive the cylindrical containers, wherein the second feed unit includes a plurality of second mandrels to receive the cylindrical containers, the second feed unit is aligned with a second image transfer location of the decorator, the second feed unit is spaced apart from the first feed unit and the first image transfer location, the second feed unit is configured to move the second cylindrical container to contact and support the second cylindrical container during transfer of the second trim to an outer surface of the second cylindrical container; and

moving an outer surface portion of the second cylindrical container into contact with the second transfer felt section at the second image transfer location, wherein the second decoration is transferred to the outer surface portion of the second cylindrical container.

14. The method of claim 11, wherein said transferring trim material from a digital printing unit further comprises ejecting ink from said inkjet print head to a first transfer blanket segment.

15. The method of claim 11, wherein the transferring trim material from the digital printing unit further comprises:

charging a conductor of an electrophotographic system;

exposing selected portions of the conductor to light to form a latent decoration;

transferring a decorative material to the latent decor, wherein the decorative material is the toner material; and

the trim material is transferred from the conductor to the first transfer felt section.

16. The method of claim 11, further comprising at least partially curing the first decoration on the first transfer blanket section using a curing unit, wherein the curing unit is located downstream of the digital printing unit but upstream of the first feeding unit.

17. The method of claim 11, further comprising at least one of:

heating the first transfer blanket section to a predetermined temperature; and

the viscosity of the decorating material supplied to the digital printing unit is adjusted.

18. The method of claim 11, further comprising accelerating the first transfer blanket section to a second speed, wherein the first and second transfer blanket sections are configured to move at the first speed adjacent the digital print unit and the first and second transfer blanket sections are configured to move at the second speed adjacent the feed unit, wherein the second speed is greater than the first speed.

19. The method of claim 18, wherein the first transfer blanket section has a leading end and a trailing end and the second transfer blanket section has a leading end and a trailing end, and wherein a distance between the leading end of the first transfer blanket section and the leading end of the second transfer blanket section varies as the speed of the first transfer blanket section changes to the second speed.

20. The method of claim 18, wherein the first transfer blanket section moves at a first speed adjacent the digital print unit and the second transfer blanket section moves at a second speed adjacent the first feed unit.