RU2757163C1 - Method and apparatus for decorating a metal container by digital printing on an offset blanket - Google Patents

Abstract

FIELD: printing.

SUBSTANCE: proposed are an apparatus and methods for decorating a metal container with an image or signs on a predetermined area of the outer surface of the body of the container. The decorator includes at least one digital printing unit, an offset blanket, and a support element. The digital printing unit transfers the decorating material to the offset blanket to form a decorative design on the offset blanket. The support element then moves the metal container in contact with the offset blanket in order to transfer the decorating material to a part of the outer surface of the metal container for decoration of the metal container. In one variant of implementation of the invention, the digital printing unit constitutes an electrophotographic system transferring the toner material to the offset blanket. In another variant of implementation, the digital printing unit includes an inkjet printing head transferring the printing ink to the offset blanket. If necessary, the decorator can include two or more support elements.

EFFECT: decoration of the outer surface of a metal container.

25 cl, 16 dwg

Description

Cross-referencing related claims

This application claims priority and priority from U.S. Patent Application 15 / 893,364, filed February 9, 2018, which is a partial continuation of the application, and claims priority and priority from U.S. Patent Application 15 / 674,363, filed August 10, 2017, which claims priority under 35 USC §119 (e) on Provisional US Patent Application No. 62 / 373,134, filed August 10, 2016, entitled "Method and Apparatus for Decorating a Metal Container Using Digital Printing on Blanket", each of which is incorporated herein by reference in its entirety.

The technical field to which the invention relates

The present invention relates generally to the decoration of containers. More specifically, the present invention provides a novel apparatus and method that uses a digital printing unit to form a decorative pattern on a blanket. The blanket is then contacted with a portion of the outer surface of the metal container, and the decoration is transferred to the outer surface of the metal container.

State of the art

Metal beverage containers offer many benefits to distributors and consumers. The metal body of the beverage container provides optimal protection for the food. For example, the metal body prevents CO ₂ migration and transmission of ultraviolet radiation, which can damage beverages, adversely affecting the taste, appearance or color of the product. Metal beverage containers also provide an impenetrable barrier to light, water vapor, oils and fats, oxygen and microorganisms, and keep the contents of the container fresh and protected from external influences, thus guaranteeing a long shelf life. The surfaces of metal containers are also ideal for decorating with brand names, logos, designs, product information and / or other preferred markings for identification, marketing and differentiation of the metal container and its contents from other products and competitors. Thus, metal containers offer manufacturers, distributors and retailers the opportunity to stand out at the point of sale.

The increased durability of metal beverage containers compared to glass containers reduces the number of containers damaged during handling and transport, resulting in additional savings. In addition, metal beverage containers are lighter than glass containers of comparable size, resulting in energy savings in transport. In addition, metal beverage containers can be manufactured with high burst pressures, making them ideal and safe for use as containers containing pressurized products such as soda and aerosol containers.

In addition, many consumers prefer metal containers over glass or plastic containers. Metal containers are particularly attractive to consumers because of their convenience. The light weight of metal containers makes them easier to carry than glass containers. Metal containers are especially suitable for public and outdoor use as they are more durable than glass containers. In addition, some consumers avoid plastic containers due to concerns that plastic can leach chemicals into consumables.

As a result of these advantages, global metal container sales in 2014 were estimated at approximately $ 53 billion. A large percentage of the metal container market is driven by beverage containers. According to one report, approximately 290 billion metal beverage containers were shipped worldwide in 2012. One US trade group reported that 126 billion metal containers were shipped to the US alone in 2014. To meet this demand, metal container manufacturing facilities operate on some of the fastest, if not fastest, production lines in the container manufacturing industry. Due to the high speeds of container production lines, technologies or processes that may operate in other industries or with containers made from other materials do not necessarily operate at the high speeds required for metal container production lines. Accordingly, many of the operations used to make and decorate metal containers often require specialized equipment and techniques.

Metal containers are often decorated with an image or symbolism such as a trademark, logo, product information or design, by means of contact printing, such as lithographic or offset printing. Contact printing methods and apparatus are described in US Pat. No. 3,766,851; US Pat. No. 3,960,073; US Pat. No. 4,384,518; US Pat. No. 6,550,389; US Pat. No. 6,899,998; in International Patent Application Publication No. 2012/0272846; International Patent Application Publication No. 2014/0360394; International Patent Application Publication No. 2015/0183211; in International Patent Application Publication No. 2015/0217559; in WIPO Publication No. WO 2013/113616; in WIPO Publication No. WO 2014/006517; in WIPO Publication No. WO 2014/008544; in WIPO Publication No. WO 2014/108489; and in WIPO Publication No. WO 2014/128200, each of which is incorporated herein by reference in its entirety.

Alternatively, metal containers can be decorated with a non-contact printing method. A variety of contactless printing processes are generally described in US Pat. No. 5,018,640, US Pat. No. 6,769,357, US Pat. No. 6,920,822, and US Pat. No. 7,373,878, each of which is incorporated herein by reference in its entirety.

One non-contact printing process is known as “Direct to Can”, in which a print head applies ink directly to a container. One example of this technology is generally described in US Pat. No. 9,327,493, which is incorporated herein by reference in its entirety. Some direct can printing systems may include inkjet printing units. Inkjet printing processes have been difficult to achieve at high speeds while maintaining print quality without distortion. This is because increasing the resolution of prior art decorations directly onto can printing assemblies typically reduces the speed at which metal containers can be decorated. For example, some known prior art direct can printing devices can decorate about 200 metal containers per minute with an image resolution of 180 dots per inch (dpi). However, decorating with a resolution of only 180dpi is not considered the high resolution or high quality that consumers and advertisers are looking for. Other known direct can printing devices can decorate approximately 90 metal containers per minute at 700 dpi. This speed is too slow for beverage container production lines, where production equipment, including decorators, typically needs to operate at a speed of 500-3000 metal containers per minute. More preferably, decorators can operate at a production rate of at least one thousand, and even more preferably several thousand cylindrical metal containers per minute.

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

The essence of the invention

The present invention provides various devices and methods for decorating metal containers in an economical, fast and reliable manner. One aspect of the present invention is an apparatus and method that uses digital printing units to create an image on an intermediate substrate (such as a blanket). Digital printing units create an image using decoration material. In one embodiment, the decoration material is one of ink and toner. Thereafter, the blanket transfers the image to a portion of the outer surface of the metal container, the end cap of the metal container, a screw cap with a first tamper evident (ROPP) mechanism, or a castellated lid.

In one embodiment of the invention, digital printing units comprise inkjet printers or inkjet printheads that form images on a blanket. In this embodiment, the decoration material comprises an ink. In one embodiment, inkjet printers transfer at least one color or type of ink onto the blanket. In another embodiment, one or more inkjet printers can transfer more than one color or type of ink onto a blanket.

In one embodiment, the device can vary the viscosity of the ink that is carried by the inkjet printheads, resulting in the first ink having a first viscosity and the second ink having a second viscosity. The device can change the viscosity in one or more of the following ways: adjusting the temperature of the ink and exposing the initiators in the ink at specific wavelengths of light. If necessary, the light can be ultraviolet (UV, UV) or infrared (IR, IR). In one embodiment, the device can change the viscosity of the ink before the ink is transferred from the inkjet printhead. Additionally, or alternatively, the device can change the viscosity of the ink after it is emitted from the inkjet print head and before the ink is transferred to the blanket. Accordingly, the device can control the temperature of the printing ink without heating the printing blanket.

Additionally, or alternatively, the device can change the viscosity of the printing ink after the ink is transferred by the inkjet printhead to the blanket. In one embodiment of the invention, the apparatus includes a temperature control device configured to heat or cool the blanket to a predetermined temperature. Optionally, in another embodiment, the device includes an emitter for exposing the initiators in the printing ink on the blanket to light of a specific wavelength, such as light of one or more wavelengths of UV light and IR light. In each of these methods, the device can change the viscosity of the printing ink on the blanket.

In another embodiment of the invention, one or more digital printing units may comprise electrophotographic digital printing units with an electrophotographic drum for forming images on a blanket. Electrophotographic digital printing units use a toner material that is applied to an electrophotographic drum to form an image. The image formed from the toner is then transferred to a blanket and then to a metal container. In one embodiment, the device includes a plurality of electrophotographic digital printing units. If necessary, each of the electrophotographic digital printing units forms a part of the image. In one embodiment, electrophotographic digital printing units transfer toner of the same color or type onto a blanket. In another embodiment, one or more of the electrophotographic digital printing units can transfer more than one color or type of toner to the blanket.

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

If necessary, the toner can be a fine powder. In one embodiment, the toner can be electrically charged. In another embodiment, the toner has a polarity that is opposite to that of the electrical charge of the electrophotographic drum. In one embodiment, the toner may include a carrier. If necessary, the carrier contains 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. Additionally or alternatively, the carrier particles can be electrically charged.

Another aspect of the present invention is a decorator that includes at least one digital printing unit configured to form a decoration on a blanket. The decorative design contains a decorative material, which is subsequently transferred from the blanket to the area of the outer surface of the metal container. In one embodiment, the decorating material comprises toner particles. In another embodiment, the decoration material comprises an ink. As will be understood by a person skilled in the art, the apparatus and methods described herein can be used on any type of surface or container, and are not limited to cylindrical metal containers. Accordingly, the apparatus and methods of the present invention can be used to decorate a lid for a container, such as, but not limited to, an end closure adapted to interlock with the neck of a container, a screw cap with a first opening control (ROPP) mechanism adapted to interconnection with a threaded container neck; or a castellated lid adapted for interconnection with the container neck.

Another aspect of the present invention is to integrate the benefits of digital printing into a high speed metal container decorating system. Another aspect of the present invention is a high speed decorator that eliminates the problems and downtime associated with plate exchange and registration and can effectively decorate small batches of decorated metal containers or multiple metal containers, each decorated with a unique decoration. Another aspect of the present invention is a method and apparatus that provides accurate, distinct and variable decoration of metal containers while minimizing or eliminating equipment switching and downtime on a high speed metal container production line. The decorator can be used to transfer decoration to one or more objects from a metal container, an end cap for a metal container, a first tamper evident screw cap (ROPP) closure, and a castellated lid. More specifically, in one embodiment of the invention, the decorator includes a digital printing unit that generates a decoration comprising a decoration material on a blanket. Subsequently, the blanket transfers the decoration to one of the objects from among the metal container, the ROPP closure and the crown lid. In one embodiment, the blanket is a continuous loop or ribbon of material. The decoration can be made from at least one of ink and toner materials. In one embodiment, the digital printing unit includes an inkjet printhead that generates decoration using ink. In another embodiment, the digital printing unit is an electrophotographic system that forms decoration using toner.

Another aspect of the present invention is a decorator configured to deliver a first ink onto a blanket and then transfer a second ink onto a blanket while the first ink is wet or uncured. Thus, the decorator can be configured to form the decoration on the blanket containing the first and second printing ink. The decorator can further transfer the decoration from the blanket to the outer surface of the metal container. If necessary, the decorator can transfer two to ten printing inks onto the blanket to form a decorative pattern while maintaining one or more printing inks in an uncured state. After the decoration is formed by two or more printing inks, the two or more decoration inks can be cured with a curing unit. In one embodiment, the decorator can transfer from two to ten * printing inks to the blanket prior to curing the first ink of two to eight printing inks. If necessary, one or more of the printing inks can be cured, or at least partially cured while they are on the blanket.

The decorator may include a first digital printing unit for transferring the first ink. The second digital printing unit can carry the second ink. If necessary, the first and second digital printing units are arranged such that the first digital printing unit transfers the first ink, and then the second digital printing unit transfers the second ink.

In one embodiment of the invention, the first and second digital printing units comprise inkjet printheads. The first inkjet printhead is configured to transfer the first ink onto the blanket. The second inkjet printhead is configured to transfer the second ink onto the blanket prior to curing the first ink. If necessary, the first and second printing inks have the same color.

The decorator can adjust the viscosity of each ink among the first and second ink. For example, in one embodiment of the invention, the decorator adjusts the first ink to a first viscosity value. The second ink is adjusted to a different, second viscosity value with a decorating device. Thus, the first ink may have a first viscosity when transported by the first digital printing unit, and the second ink may have a second viscosity when transported by the second digital printing unit.

In one embodiment of the invention, changing or adjusting the viscosities of the first and second ink changes the size of the dots or drops of the first and second ink, whereby the first and second ink can be transferred to the blanket in close proximity to each other to form a decoration , while the first and second printing inks are wet or uncured. Additionally or alternatively, changing the viscosity of the first ink prevents inadvertent or unwanted movement of dots or drops of the first ink on the blanket so that the second ink can be transferred to the blanket before the first ink cures.

In one embodiment of the invention, the decorator is configured to vary the temperature of the first and second ink to adjust the viscosity of the ink. Digital printing units may include a temperature control device for changing the temperature of the ink. If necessary, the decorator control system can send a signal to a temperature control device interacting 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 the first temperature controller to heat (or cool) the first ink to a first temperature, and send a second signal to a second temperature controller to cool (or heat) the second ink to a second temperature. Thus, the viscosity values of the first and second ink can be controlled.

Additionally or alternatively, the decorator can activate one or more initiators in the ink to change the viscosity of the ink. In one embodiment, the initiators are photoinitiators. More specifically, in one embodiment, initiators are activated by exposure to light of a given wavelength. If necessary, initiators are activated by UV light of a given wavelength. The decorator may include at least one light source configured to emit light of a predetermined wavelength to activate initiators in the ink. Accordingly, the decorator can change the viscosity of the ink. In one embodiment, light can change the viscosity of the ink before the ink is transferred from the inkjet printhead. Optionally, in another embodiment, the light can change the viscosity of the ink after the ink has been transferred to the blanket.

In one embodiment, the decorator includes a temperature control device configured to heat or cool the blanket to a predetermined temperature. Thus, the size of the ink droplets on the blanket can be changed. Additionally or alternatively, the moisture content of the printing ink on the blanket can be changed.

Another aspect of the present invention is a device for applying decoration to the outer surface of a metal container, comprising: (1) a first segment of a blanket; (2) a digital printing unit with a predetermined alignment with respect to the first segment of the blanket, the digital printing unit being adapted to transfer the decoration material to the first segment of the blanket to form a decoration on the first segment of the blanket; and (3) a supply unit for moving the metal container in contact with the first blanket segment for transferring decoration from the first blanket segment to the outer surface of the metal container. In one embodiment, the first blanket segment may be spaced a first distance from the second blanket segment in the vicinity of the digital printing unit. Additionally, or alternatively, in another embodiment, the first blanket segment may be spaced a second distance from the second blanket segment in the vicinity of the feed module. In one embodiment, the first distance is less than the second distance. In another embodiment, the first blanket segment is adjacent to the second blanket segment. More specifically, the first blanket segment may be sequentially positioned with a second blanket without a third blanket segment between the first and second blanket segments.

Additionally or alternatively, the first and second blanket segments may be movable at a first speed in the vicinity of the digital printing unit. If necessary, the first and second segments of the blanket can be made with the possibility of moving at a second speed in the vicinity of the feed unit. In one embodiment, the first speed is slower than the second speed.

In one embodiment, the first and second blanket segments are part of a continuous loop of material. Accordingly, the first and second blanket segments can define portions of a single blanket. Alternatively, in another embodiment, the first and second blanket segments can be separate blanket segments.

The decoration material can be at least one of an ink and a toner. In one embodiment of the invention, 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.

Additionally or alternatively, in one embodiment of the invention, the device includes an inkjet printhead. The inkjet printhead can be configured to transfer the ink-containing decorating material to one or more of the first and second segments of the blanket. If necessary, the device can include a thermal system configured to adjust the viscosity of the ink. Additionally or alternatively, in one embodiment, the device may include an ultraviolet system configured to adjust the viscosity of the ink.

The device may include a curing unit. In one embodiment of the invention, the curing unit may be located downstream of the digital printing unit. If necessary, the curing unit can be located upstream of the feed unit. The curing unit can be configured to at least partially cure the decoration material transferred to the first blanket segment. In one embodiment, the curing unit can at least partially cure the decoration material on the first segment of the blanket before the decoration material can be transferred to the metal container.

Additionally or alternatively, the device may include a temperature control device configured to adjust the temperature of one or more of the first and second blanket segments. If necessary, the temperature can be selected to change the viscosity of the decoration material. In one embodiment of the invention, the temperature control device may be configured to contact the first and second blanket segments. In another embodiment, the temperature control device is configured to adjust the temperature of one or more of the first and second blanket segments without contacting the blanket segments.

The device may include a plurality of digital printing units, each of which is configured to transfer one or more colors of the decorating material and various decorative designs to the first and second segments of the blanket. Optionally, in one embodiment of the invention, the device further comprises a second feed unit. The second supply unit may be configured to move the second metal container into contact with the second blanket segment to transfer the second decoration from the second blanket segment to the outer surface of the second metal container. In one embodiment, the feed unit is located upstream of the second feed unit. If necessary, the feed unit can be aligned with the first transfer position. Additionally or alternatively, the second feed unit can be aligned with the second transfer position.

Another aspect of the present invention is to provide a method for forming decoration on a portion of the outer surface of a cylindrical container. The method typically includes, but is not limited to, one or more of the following: (1) transferring the decorating material from the digital printing unit to the first printing blanket segment of the decorating device, whereby the decorating material forms decoration on the first blanket segment, moreover, the decorating material contains at least one of the ink and the toner material; (2) providing a cylindrical container; (3) positioning the cylindrical container in the decorating device supply unit; (4) changing the distance between the first blanket segment and the second blanket segment as the first and second blanket segments move from the digital printing unit to the feeding unit; and (5) moving a portion of the outer surface of the cylindrical container into contact with the first segment of the blanket. Thus, the decoration can be transferred from the first segment of the blanket to a portion of the outer surface of the cylindrical container. In one embodiment of the invention, the first blanket segment may be spaced a first distance from the second blanket segment in the vicinity of the digital printing unit. Optionally, in another embodiment, the first blanket segment can be spaced a second distance from the second blanket segment in the vicinity of the feed unit. In one embodiment, the second distance is greater than the first distance. In another embodiment, the first blanket segment is adjacent to the second blanket segment. More specifically, in one embodiment, the first and second blanket segments may be sequentially positioned in the decorator.

Additionally or alternatively, in another embodiment of the invention, the first and second blanket segments may be movable at a speed that is variable. In one embodiment, the first and second blanket segments can move at a first speed in the vicinity of the digital printing unit. Optionally, in another embodiment, the first and second blanket segments may be movable at a second speed in the vicinity of the feed unit. In one embodiment, the second speed may be greater than the first speed. Accordingly, in another embodiment, the method optionally includes accelerating the first segment of the blanket to a second speed.

In one embodiment of the invention, the first and second blanket segments are part of a continuous material loop. Accordingly, the first and second blanket segments can define portions of a single blanket. Alternatively, in another embodiment, the first and second blanket segments can be separate blanket segments. Optionally, the decorator can include a plurality of separate blanket segments, the first and second blanket segments comprising two of the plurality of separate blanket segments.

If desired, the method may include transferring more decoration material from the digital printing unit to a second blanket segment to form a second decoration on the second blanket segment. In addition, the method may include providing a second cylindrical container. The second cylindrical container can optionally be positioned in the second decorating supply unit. If necessary, a portion of the outer surface of the second cylindrical container can be moved to a position in contact with the second blanket segment. In one embodiment of the invention, the second feed unit may be positioned downstream of the feed unit. Thus, the second decoration can be transferred to a portion of the outer surface of the second cylindrical container.

In one embodiment of the invention, transferring decoration material from the digital printing unit further includes spraying ink from the inkjet printhead onto the first segment of the blanket. Additionally or alternatively, transferring the decoration material from the digital printing unit may include transferring the toner material from the electrophotographic system to the first segment of the blanket. The electrophotographic system can include a conductor. In one embodiment, the method includes charging the conductor. The method can also include irradiating selected portions of the conductor with light to form a hidden decoration. If necessary, the decoration material can be transferred to the hidden decoration. In this embodiment, the decoration material is a toner material. The method may also include transferring the decorating material from the conductor to the first segment of the blanket.

In another embodiment, the method may include at least partially curing the decoration. In one embodiment, the decoration can be cured while the decoration is on the first blanket segment. Curing can be accomplished with a decorator curing device. In one embodiment, the curing unit may be located downstream of the digital print unit but upstream of the feed unit.

If necessary, the method may further include heating the first blanket segment to a predetermined temperature. In another embodiment, the method may include cooling the first blanket segment to a predetermined temperature. Additionally or alternatively, the method may include adjusting the viscosity of the finishing material supplied to the digital printing unit. In another embodiment, the method may include changing the viscosity of the decorating material on the first and second blanket segments. In yet another embodiment, the viscosity of the decorating material can be adjusted by the decorating device during transfer to the first and second blanket segments.

One aspect of the present invention is a method of forming a decoration on the outer surface of a cylindrical container. The method includes, but is not limited to: (1) charging a conductor of the electrophotographic system; (2) irradiating the surface of the conductor with light to form a latent electrostatic image thereon; (3) developing a latent electrostatic image with toner to form a powder image on the surface of the conductor; (4) transferring the powder image to the blanket; and (5) transferring the powder image from the blanket to the outer surface of the cylindrical container. If necessary, the method further includes curing the powder image with a curing device. In one embodiment, the powder image is at least partially cured or pin cured * while on the blanket. In another embodiment, the powder image is cured upon transfer to the outer surface of the cylindrical container. In one embodiment, the curing unit uses heat to cure the powder image.

One aspect of the present invention is to provide an apparatus for decorating a metal preform. The device usually includes, but is not limited to: (1) a blanket; (2) a digital printing unit with a predetermined alignment with respect to the blanket, the digital printing unit being configured to apply or transfer a decoration material to the blanket; and (3) a supply unit for moving the metal blank into a position of contact with the blanket of at least a portion of the blanket decoration material onto the metal blank. Thus, the device forms decoration on a portion of the outer surface of the metal blank. Optionally, the metal blank comprises one of a metal container, an end closure for a metal container, a first tamper evident screw cap (ROPP) closure, and a castellated lid.

In one embodiment of the invention, the feed unit comprises at least a first feed unit and a second feed unit. The first feed unit is positioned relative to the blanket in the first transfer position. The second feed unit is located relative to the blanket in the second image transfer position. Thus, the alternating decoration formed by the blanket digital printing unit is transferred to the metal blanks supported by the first and second feed units. In one embodiment, a first blanket decoration is transferred to a first metal blank supported by a first supply unit. The second blanket decoration is transferred to a second metal blank supported by a second feed unit. The second decorative design is consistently positioned on the blanket with the first decorative design.

Decorations can include any marks such as, but not limited to: brand name, logo, product information, or design. Decorations can include, but are not limited to, one or more characters, an image, letters, and numbers. In one embodiment of the invention, the decoration material is a toner material and an ink. In one embodiment, the toner material comprises a fine powder.

In one embodiment of the invention, the digital printing unit includes an inkjet printhead. In another embodiment, the digital printing unit is configured to spray a plurality of ink colors onto the blanket. Alternatively, the digital printing unit is configured to supply one ink color to the blanket. If necessary, the decorator is configured to change the viscosity of the printing ink. In one embodiment, the decorator includes a temperature control device to heat or cool the ink to a predetermined temperature. The decorator can also include a temperature control device for changing the temperature of the blanket. In another embodiment, the ink supplied to the inkjet printhead includes at least a first initiator that can be activated with light of a predetermined wavelength. When activated, the first initiator can increase the viscosity of the ink. The ink can include a second initiator that can be activated with light of a second wavelength. When the second initiator is activated, the viscosity of the ink decreases. Optionally, the decorator includes a light source configured to irradiate the ink at a predetermined wavelength required to activate the first initiator. In addition, the decorator can include a second light source for irradiating the ink at a second wavelength necessary to activate the second initiator.

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

In one embodiment of the invention, a single digital printing unit forms a complete decoration on a blanket. In another embodiment, a digital printing unit includes two to ten digital printing units. If necessary, each of the two to ten digital printing blocks forms part of the decoration on the blanket.

In one embodiment of the invention, the blanket comprises a single continuous sheet or loop of material such as a belt. In another embodiment, the blanket comprises a plurality of discrete blanket segments. In one embodiment, the individual blanket segments are interconnected to a common blanket wheel. If necessary, the individual segments of the blanket can change the speed after the digital printing unit applies the decoration material to the blanket. Thus, a single segment of the blanket can correspond to the speed of the outer surface of the metal blank in the feed unit. In another embodiment, the individual blanket segments have a first spacing in the vicinity of the digital printing unit, and a second greater spacing in the vicinity of the feed unit.

In one embodiment, each blanket segment is positioned at the distal end of a blanket support extending from the blanket wheel. Supports of the blanket are made with the possibility of changing the position of their respective segments of the blanket relative to the blanket wheel. In one embodiment, the distance between the blanket wheel and the blanket segment can be changed by moving the corresponding blanket support. In another embodiment, the blanket support can move the associated blanket segment radially relative to the blanket wheel. If necessary, the blanket support can be rotated relative to the blanket wheel. In one embodiment, the blanket support includes a first section pivotally coupled to a second section. In another embodiment, the blanket support is of variable length. Additionally, or alternatively, the blanket wheel may include a recess or hole to receive at least a portion of the blanket support. Accordingly, the blanket support can retract or extend from the blanket wheel.

In one embodiment of the invention, the device includes at least one tensioner for adjusting the tension of the blanket. The tensioner can improve the performance of the device by increasing the tension to accommodate wear or stretching of the blanket. If necessary, the tension of the blanket is selected to counteract the force generated from the metal blank during transfer of the decoration material onto the metal blank. In one embodiment, the tensioner may be adjustable relative to the inner surface of the blanket. If necessary, the tensioner is positioned in the vicinity of the transfer position, in which the decoration material on the outer surface of the blanket is transferred to the metal blank. In one embodiment, the tensioner may interact with an actuator. The actuator can change the position of the tensioner in response to a signal received from the control system.

Optionally, in another embodiment of the invention, the device may include one or more of a control system, a curing module, and a cleaning system. The cleaning system is configured to remove residual decoration material from the blanket after the metal blank contacts the blanket to receive the decoration generated by the digital printing unit.

The control system communicates with at least the digital printing unit and the feed unit. In addition, the control system can send a signal to the digital printing unit to create decoration. In one embodiment of the invention, the control system can send a signal to the digital printing unit to create a variety of unique decorations. In response to receiving the signal, the digital printing unit will transfer the decoration material onto the blanket to form the decoration on the blanket. The decoration material can comprise one or more toner and ink materials. The blanket then transfers the decoration material to the outer surface of the metal blank. Thus, the device can decorate a variety of metal blanks with unique decorative options at a high rate of speed.

If necessary, the control system can send a signal to the digital printing unit to change the viscosity of the ink that will be transferred from the digital printing unit. The control system can also send a signal to the temperature control device to change the temperature of the blanket. Thus, the temperature control device can heat or cool the blanket to a predetermined temperature. In one embodiment, the control system can change the position of the blanket support, for example by guiding the blanket support pivotally relative to the blanket wheel. Additionally or alternatively, the control system can send a signal to an actuator that is functionally associated with the blanket support. This signal can cause the actuator to move the support in a specific direction. The control system can also cause the blanket support to move so that the distance between the blanket segment and the blanket wheel changes. In one embodiment of the invention, the control system can cause a change in the length of the blanket support. In another embodiment, the control system may send a signal that causes the blanket support to retract or extend from the blanket wheel.

In one embodiment, the curing block can at least partially cure or pin cure the decorating material. In another embodiment, the curing unit at least partially cures the decoration material on the blanket before the decoration is transferred to the metal blank. If necessary, the device can include a plurality of curing units. In one embodiment, a curing unit interacts with each of the digital printing units. In another embodiment, the apparatus includes one curing unit for curing or at least partially curing the decoration after the decoration has been formed with one or more digital printing units. Thus, the curing unit can at least partially cure the decoration while the decoration is on the blanket. Optionally, in another embodiment, the curing unit cures the decoration after the decoration has been transferred from the blanket to a portion of the outer surface of the metal blank. In one embodiment, the curing unit is configured to cure the ink. In another embodiment, the curing unit is configured to cure one or more of ultraviolet-curable ink, water-based heat-curable ink, and mineral oil-based heat-curable ink. In one embodiment, the curing unit is configured to cure the particulate toner material.

Another aspect of the present invention is to provide a method for decorating a portion of the outer surface of a container. The method includes, but is not limited to: (1) providing a container; and (2) decorating the container with a decorating device, which includes: (a) a digital printing unit; and (b) a transfer blanket with a predetermined alignment with the digital printing unit, whereby the blanket receives decoration material from the digital printing unit. Accordingly, when a portion of the outer surface of the container is brought into contact with the blanket, at least a portion of decorating material from the blanket is transferred to the container to form a decoration on a portion of the outer surface of the container. In one embodiment, a portion of the outer surface of the container comprises one of the container body portions, a closed container end, an end closure for the container, a first tamper evident screw cap (ROPP) closure, and a castellated lid. If desired, the decoration material can be one or more of toner and ink.

In one embodiment of the invention, the digital printing unit comprises one of an inkjet printhead and an electrophotographic drum, or printing plate. In another embodiment, the digital printing unit is configured to spray a plurality of ink colors onto the blanket. Alternatively, the digital printing unit is configured to jet a single ink color onto a blanket. In another embodiment, the digital printing unit is configured to transfer toner onto a blanket. In one embodiment, the toner carried by the digital printing unit contains a plurality of colors.

In one embodiment of the invention, a single digital printing unit forms a complete decoration on a blanket. In another embodiment, a digital printing unit includes two to ten digital printing units. In one embodiment, each of the two to ten digital printing units may form part of the decoration on the blanket. In another embodiment, each of the two to ten digital printing units can transfer a different ink color or a different image onto the blanket. In one embodiment, two to ten digital printing units comprise one or more of an inkjet printhead and an electrophotographic drum.

In another embodiment of the invention, the blanket comprises a plurality of discrete blanket segments. In this embodiment, the method may further include changing the position of the blanket segment relative to the blanket wheel. In one embodiment, the method includes changing the distance between the blanket segment and the blanket wheel. In another embodiment, the method may include rotating a blanket support and an associated blanket segment relative to a blanket wheel. If necessary, the method can further include changing the gap or distance between adjacent segments of the blanket. In one embodiment, adjacent blanket segments have a first gap in the vicinity of the digital printing unit and a second gap at an image transfer position where the container is brought into contact with the blanket. Alternatively, in yet another embodiment, the blanket comprises a single continuous sheet or loop of material.

In one embodiment of the invention, the blanket contains one material from a photopolymer material or a compound containing at least partially saturated polymethylene chain. In another embodiment, the saturated polymethylene chain of the blanket comprises ethylene propylene diene monomer rubber, known to those skilled in the art as EPDM rubber. In yet another embodiment, the blanket includes a face containing a rubber material known as nitrile butadiene rubber.

If necessary, the method can include changing the viscosity of the ink interacting with the digital printing unit. In one embodiment of the invention, the method includes activating an initiator in an ink to change the viscosity of that ink. In another embodiment, the method includes heating and cooling an ink to change the viscosity of the ink. Additionally or alternatively, the method may further include adjusting the temperature of the blanket. The temperature of the blanket can be adjusted before or after the decoration material is transferred to the blanket by the digital printing unit.

In one embodiment of the present invention, the decorator optionally includes one or more of a supply unit, a control system, a curing unit, and a purification system. The feed unit is configured to move the container to a predetermined alignment position with respect to the blanket. In one embodiment, the feed unit receives a container from upstream equipment. The upstream equipment may include a surface treatment unit.

Optionally, the decorator can include a first feed unit and a second feed unit. In one embodiment, the method may further comprise: (a) forming a first decoration, a second decoration, and a third decoration on a blanket using a digital printing unit; (b) moving, with the first supply unit, the first container into a position of contact with the blanket so that the first decoration is transferred to the first container; (c) moving, with the second feed unit, the second container into a position of contact with the blanket such that the second decoration is transferred to the second container; and (d) moving, with the first delivery unit, the third container to a position of contact with the blanket so that the third decoration is transferred to the third container. In one embodiment, the first, second and third decorations are formed sequentially on the blanket. Thus, the first and third decorations can be transferred to the first and third containers when supported by the first supply module. Likewise, the second decoration can be transferred to the second container when supported by the second supply unit.

The cleaning system is in a predetermined orientation with respect to the blanket. In one embodiment of the invention, the cleaning system is configured to remove residual decoration material from the blanket after the container is brought into contact with the blanket to obtain the decoration generated by the digital printing unit.

The control system communicates with one or more of the digital printing unit and feed unit. In addition, the control system can send a signal to the digital printing unit to create decoration. In one embodiment, the control system can send a signal to the digital printing unit to create a variety of unique decorations that the digital printing unit will generate on the blanket. In one embodiment, the decoration formed by the digital printing unit comprises at least one ink and toner component. Thus, a decorator can decorate many containers with unique decorations.

In one embodiment of the invention, the curing unit can at least partially cure the decoration on the blanket before the decoration is transferred to the container. Alternatively, in another embodiment, the curing unit cures the decoration on the container. The decorator can include multiple curing blocks as needed. Optionally, the decorator may include a first digital printing unit and a second digital printing unit. The first digital printing unit can transfer the first decoration material to one or more of the first, second and third decoration locations. The second digital printing unit can transfer the second decoration material to one or more of the first, second and third decoration locations. In one embodiment, a curing unit interacts with each of the first and second digital printing units. In another embodiment, the decorator includes one curing unit for curing or at least partially curing the decoration after the decoration has been formed with 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 decorations after the first and second digital printing units have transferred their respective first and second decoration materials to the blanket. In one embodiment, the curing unit is configured to at least partially cure the first, second and third decorations while the decoration material of the first and second digital printing units is on the blanket. Alternatively, in another embodiment, the curing unit is configured to at least partially cure the first, second and third decorations after the decoration material has been transferred from the blanket to the respective first, second and third containers. In yet another embodiment, the curing unit is configured to cure one or more of a toner, an ultraviolet-curable ink, a water-based ink, and an oil-based ink such as a mineral oil ink.

Another aspect of the present invention is a container decorated with a decorative pattern formed by an electrophotographic system on an intermediate substrate such as a blanket. The container includes, but is not limited to: (1) the bottom; (2) a body portion extending upwardly from the bottom portion, the body portion including an outer surface portion; (3) a hole positioned at the very top of the body; and (4) a decoration on a portion of the outer surface, a decoration comprising a digital image formed with toner transferred to a blanket using an electrophotographic system, wherein when a portion of the outer surface of the container rotates in contact with the blanket, the toner on the blanket transferred to the area of the outer surface of the container. In one embodiment, the toner is solidified after being transferred to a portion of the outer surface of the container.

In one embodiment, the decoration has a resolution of at least about 1600 by 1600 dpi. In another embodiment, the decoration comprises up to five toner colors. In yet 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 yet another embodiment, the container is made of one or more of aluminum, steel, tin, plastic, paper, and glass.

Another aspect of the present invention is a method of forming a decoration on a portion of the outer surface of a first cylindrical container. The method includes one or more of the following, but is not limited to: (1) transferring a decorating material from a digital printing unit to an offset blanket of a decorating device, the decorating material defining the decorative design; (2) providing a first cylindrical container; (3) positioning the first cylindrical container in the decorating supply unit; and (4) moving a portion of the outer surface of the first cylindrical container to a position of contact with the blanket. Thus, the decoration material defining the decoration is transferred from the blanket to a portion of the outer surface of the first cylindrical container. In one embodiment, the decoration material comprises at least one of an ink and a toner material.

In one embodiment of the invention, the blanket comprises a plurality of discrete blanket segments. If necessary, the individual segments of the blanket are made with the ability to correspond to the rotation speed of the first cylindrical container positioned in the feed unit. In another embodiment, the blanket is a continuous loop of material.

In one embodiment, the decorator further comprises one or more of a cleaning system and a curing unit for at least partially curing the decorating material. The cleaning system is designed to remove the residues of the finishing material from the blanket. If necessary, the curing unit is configured to at least partially cure one or more materials from toner material, UV curable ink, water-based ink, and mineral oil ink.

In one embodiment of the invention, the curing unit is configured to at least partially cure the decoration material on the blanket. If necessary, the curing unit can cure the decoration material transferred to the blanket from two or more digital printing units. More specifically, in one embodiment, a curing unit may cure a decoration material onto a blanket of two or more digital printing units. Accordingly, in one embodiment, the curing unit is located downstream of all digital printing units. Thus, a wet or uncured decoration material transferred to a blanket by one or more digital printing units can be at least partially cured with a single curing unit. In one embodiment, the second decoration material is transferred to the blanket before the first decoration material on the blanket is cured. In another embodiment, the curing unit is configured to at least partially cure the decoration material after the decoration material has been transferred to a portion of the outer surface of the first cylindrical container.

In one embodiment, the feed unit includes a plurality of rotatable mandrels. In one embodiment, the mandrels are rotated such that the first cylindrical container rotates at a speed substantially equal to that of the blanket.

Optionally, the decorating supply unit comprises at least a first supply unit and a second supply unit. In one embodiment, the digital printing unit is configured to sequentially form a first decoration and a second decoration from a decoration material on a blanket. The first feed unit is aligned with the blanket to transfer the first decoration to the first cylindrical container. The second feed unit is aligned with the blanket to transfer the second decoration to the second cylindrical container. The first feed unit can be positioned to move the cylindrical containers in contact with the blanket at the first transfer position. The second feed unit is positioned to move the cylindrical containers in contact with the blanket at the second transfer position.

In another embodiment of the invention, the decorator includes a tensioning mechanism configured to contact the blanket. If necessary, the method may further include adjusting the blanket tensioner. For example, the control system can send a signal to an actuator that interacts with the tensioner. The signal can cause the tensioner to move in a specific direction by the actuator.

In one embodiment of the invention, the digital printing unit comprises an electrophotographic system. The method may further include charging a conductor of the electrophotographic system, exposing selected portions of the conductor to light to form the hidden decoration, transferring the decoration material to the hidden decoration in which the decoration material is a toner material, and transferring the decoration material from the wire to the blanket. Thus, the electrophotographic system can form decoration on the blanket.

In another embodiment of the invention, the control system is in communication with the decorating device. The method may further comprise: creating a decoration by the control system. If necessary, the method may include: sending a signal from the control system to the digital printing unit. The signal can cause the decoration material to be transferred from the digital printing unit to the blanket. In another embodiment, the method may include: sending a signal from the control system to the temperature control device. The signal can cause the temperature control device to perform one or more of the following: (i) change the temperature of the ink; and (ii) changing the temperature of the blanket. In another embodiment, the method optionally includes sending a signal from the control system to change the viscosity of the ink. In one embodiment, the signal causes the light source to generate light at a predetermined wavelength. The light activates the initiator in the ink. When activated, the initiator increases or decreases the viscosity of the ink. The light source can be positioned so that the light contacts the ink before the ink is transferred to the blanket. In another embodiment, the light source is positioned to generate light that contacts the ink on the blanket. In yet another embodiment, the light source is positioned to generate light that hits the ink as it is ejected from the inkjet print head and before the ink contacts the blanket.

Another aspect of the present invention is to provide a decorating device with two or more supply units. The feed units can be positioned such that the alternating decoration formed on the blanket is transferred to metal containers supported by the feed units. In one embodiment of the invention, the first feed unit transfers every second decoration on the blanket to metal containers. More specifically, the first supply unit can cause the transfer of the first decoration and the third decoration from successive decorations on the blanket to metal containers supported by the first supply unit. The second feed unit can cause the second decoration and the fourth decoration from successive decorations to be transferred to metal containers supported by the second delivery module.

In another aspect, the decorator may include a blanket with two or more blanket segments that are positioned from edge to edge. Each segment of the blanket forms an endless cycle. Segments of the blanket can be decorated with one or more digital printing units. Subsequently, the segments of the blanket can move past two or more support elements. Each support element can move the metal containers into contact with the decoration material on one of the blanket segments. In one embodiment, the decorator includes two blanket segments and two support members. Each pivot element interacts with one of two common segments. Thus, a decorator can decorate metal containers from two production runs. In another embodiment, the decorator includes four support members and four blanket segments that are endless loops. Each support element interacts with one of four blanket segments.

Another aspect is to provide a blanket wheel decorator that includes blanket supports extending therefrom. The blanket segment interacts with each blanket support. In one embodiment, the blanket supports are of variable length. Thus, the position of the blanket segment located on the blanket support can change as the blanket wheel rotates. In the first position, the segment of the blanket can be at a first distance from the blanket wheel. In the second position, the segment of the blanket can be at a second distance from the blanket wheel. In another embodiment, the blanket supports are pivotally connected to the blanket wheel. In yet another embodiment, one or more blanket supports include a mechanical connection. Accordingly, the blanket support can bend or move the associated blanket segment when the blanket wheel rotates.

Another aspect of the present invention is a decorator with a curing unit configured to cure a decorating 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 decorating material onto a decorating blanket, the first decorating material forming at least a portion of the first decoration; (2) a second digital printing unit adapted to transfer a second decorating material onto a blanket, the second decorating material forming at least another part of the first decorative design; and (3) a curing unit for at least partially curing the first and second decoration materials. In one embodiment, the second digital printing unit transfers the second decorating material to the blanket closest to the first decorating material before the first decorating material is cured by the curing device. In one embodiment, the curing unit is located downstream of the second digital printing unit. More specifically, in one embodiment, the curing unit is positioned between the second digital printing unit and the image transfer position of the decorating device.

In one embodiment of the invention, the curing unit is configured to cure the first and second decoration materials on the blanket. In another embodiment, the curing unit is configured to cure the first and second decoration materials on the outer surface of the cylindrical container.

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

In one embodiment, the first and second digital printing units comprise first and second inkjet printheads. The decorator is configured to change the viscosity of the first and second ink corresponding to the first and second inkjet printheads. 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 ink supplied to the first and second inkjet printheads.

Additionally or alternatively, the first and second ink can include initiators that are activated by light at predetermined wavelengths. When activated, the first initiator can increase the viscosity of the ink. The second initiator, when activated, can reduce the viscosity of the ink. The decorator can include light sources that interact with the first and second inkjet printheads. The first light source can generate light of one or more predetermined wavelengths to selectively activate at least one of the first and second initiators in the first ink. The second light source can interact with the second inkjet printhead to selectively activate the first and second initiators in the second ink.

One aspect of the present invention is a device for applying decorations to the outer surfaces of metal containers. The device includes, but is not limited to: (1) a blanket; (2) a digital printing unit with predetermined alignment with respect to the blanket, the digital printing unit being configured to transfer a decorating material to the blanket to form at least a portion of the first decoration and the second decoration on the blanket; (3) a first supply unit to move the first metal container into a position of contact with the blanket for transferring the first decoration from the blanket to the outer surface of the first metal container; and (4) a second supply unit for moving the second metal container into a position of contact with the blanket for transferring the second decoration from the blanket to the outer surface of the second metal container. The decoration material includes at least one of ink and toner. In one embodiment, the blanket is a continuous loop of material. Alternatively, the blanket contains a plurality of individual blanket segments. The first feed unit may be aligned with the first transfer position of the device, and the second supply unit may be aligned with the second transfer position of the device.

In one embodiment of the invention, the apparatus comprises a plurality of digital printing units. Each of the digital printing units is configured to transfer one or more different colors of the decorating material and other decorative design to the blanket.

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

In one embodiment of the invention, the device includes a temperature control device configured to adjust the temperature of the blanket. The temperature control device can heat or cool the blanket to a predetermined temperature. If necessary, the viscosity of the decorating material changes when the temperature control device regulates the temperature of the blanket.

In one embodiment of the invention, the digital printing unit is an electrophotographic system comprising a conductor, a charging element, an exposure element, and a developing unit that supplies a decoration material containing toner. In another embodiment, the digital printing unit is an inkjet printhead and the decoration material is ink. The device may further include one or more of a thermal system and an ultraviolet irradiation system configured to adjust the viscosity of the ink.

Another aspect of the present invention is a method of forming a decoration on a portion of the outer surface of a cylindrical container. The method usually includes one or more of the following, but is not limited to: (1) transferring a decorating material from at least two digital printing units onto a blanket of a decorating device, whereby the decorating material forms a decoration on the blanket ; (2) at least partially curing the decoration on the blanket with a curing unit; (3) providing a cylindrical container; (4) positioning the cylindrical container in the first decorating supply unit; and (5) moving a portion of the outer surface of the cylindrical container to a position of contact with the blanket. Thus, the decoration is transferred from the blanket to the area of the outer surface of the cylindrical container. The decoration material may comprise at least one of an ink and a toner. If necessary, the blanket contains one of a plurality of individual blanket segments and a continuous material loop.

The method may further include rotating the blanket segment relative to the decorating blanket wheel. Additionally or alternatively, the method can include changing the distance between the blanket segment and the blanket wheel.

In one embodiment, the method includes one or more of the following: (i) transferring more decoration material from at least two digital printing units onto the blanket to form a second decoration on the blanket; (ii) providing a second cylindrical container; (iii) positioning the second cylindrical container in the second decorating supply unit; and (iv) moving a portion of the outer surface of the second cylindrical container to a position of contact with the blanket at a location downstream of the first supply unit. Thus, the second decoration is transferred to a portion of the outer surface of the second cylindrical container at a second transfer position of the decorator, which is different from the first transfer position associated with the first supply unit.

The curing unit can be positioned downstream of at least two digital printing units. If necessary, the curing unit is configured to cure one or more of a toner material, an ultraviolet-curable ink, a water-based ink, and a mineral oil-based ink. In one embodiment, the curing unit is located upstream of one or more of the first and second image transfer locations.

In one embodiment of the invention, transferring decoration material from at least two digital printing units further comprises one or more of: (a) charging a conductor of the first of the at least two digital printing units, the first digital printing unit being electrophotographic system; (b) irradiating selected portions of the conductor with light to form a hidden decoration; (c) transferring a decoration material to a hidden decoration, the decoration material being a toner material; and (d) transferring the decorating material from the conductor to the blanket.

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

The method may further comprise heating the blanket to a predetermined temperature. Additionally or alternatively, the method may include adjusting the viscosity of a decoration material supplied to at least one of at least two digital printing units, the decoration material being an ink. In one embodiment of the invention, adjusting ink viscosity includes one of heating or cooling the ink. In another embodiment, adjusting ink viscosity 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 invention is to provide a decorating device for decorating metal containers. A decorator generally includes, but is not limited to: (1) a rotatable blanket wheel; (2) spokes extending generally radially from the blanket wheel, each spoke having a distal end spaced from the blanket; (3) a segment of blanket connected to the distal end of each spoke; (4) a digital printing unit adapted to transfer decorating material to the blanket segments when the blanket wheel rotates the spokes passing by the digital printing unit, the decorating material forming a decoration on each blanket segment; and (5) a supply unit for moving the metal container into contact with the blanket segment for transferring decoration to the outer surface of the metal container. If necessary, the distance between the blanket wheel and the blanket segments at the distal end of each spoke is adjustable.

In one embodiment, the length of each spoke is adjustable. In another embodiment, each spoke can be retracted at least partially into a blanket wheel. Additionally or alternatively, the spokes can be rotated relative to the blanket wheel.

In another embodiment, each spoke includes a first section coupled to a blanket wheel and a second section including a distal end. The first section can be pivotally connected to the second section.

In one embodiment, the distal ends of the spokes are movable with respect to the blanket wheel. Accordingly, the first blanket segment connected to the first spoke and the second blanket segment connected to the second spoke may be separated by a first distance in the vicinity of the digital printing unit. As the blanket wheel rotates, the distal ends of the spoke move so that the first and second blanket segments can be separated by a second distance in the vicinity of the feed unit.

Although commonly referred to herein as a "metal container", "beverage container", "can" and "container", it should be appreciated that the present invention can be used to decorate containers of any size or shape, including yourself, but not limited to, beverage cans, beverage bottles, food cans, and aerosol containers. Accordingly, the term "container" is intended to encompass any type of container for any product and is not specifically limited to a beverage container such as a soft drink or beer can. Containers can also be in any state of the manufacturing process. In addition, the container can be formed by a drawing-and-ironing process or an impact stamping process. Thus, the present invention can be used to decorate a "cup" that is subsequently formed into a finished container, a "blank bottle" that is subsequently formed into a metal bottle or "tube" that is formed into an aerosol container body. In addition, the present invention can be used to decorate any part of the container. For example, in one embodiment of the present invention, a decorator may be used to decorate a portion of the outer surface of a container including one or more of a closed end portion and a portion of the outer surface of a container body portion. In another embodiment of the present invention, the decorator may decorate a portion of the outer surface of the end closure that is adapted to interlock with the neck of the container. In yet another embodiment, the outer surface of a first tamper evident closure (ROPP) screw closure adapted to be connected to a threaded container neck may be decorated with a decorating device of the present invention. In yet another embodiment, the decoration material can be transferred to a portion of the outer surface of the castellated lid that is adapted to be connected to the neck of the container.

The terms "metal" or "metallic" as used herein refer to any metallic material that can be used to form a container, including but not limited to aluminum, steel, tin, and any combination thereof. However, it should be appreciated that the apparatus and method of the present invention can be used to decorate containers formed from any material, including paper, plastic and glass. In addition, while the methods and apparatus of the present invention are generally described in connection with decorating metal containers in general with a cylindrical body, it will be appreciated that the methods and apparatus of the present invention can be used to decorate any type of substrate, including a continuous web or sheet of metal. , plastic or paper.

The phrases "at least one", "one or more" and "and / or" as used herein are open-ended expressions that, when used simultaneously, are conjunctive and disjunctive. 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 only A, only B, only C, A and B together, A and C together, B and C together, or A, B and C all together.

Unless otherwise indicated, all numbers expressing quantities, sizes, conditions, etc. used in the description and the claims are to be understood as being modified in all cases by the terms "about" or "approximately". Accordingly, unless otherwise indicated, all numbers expressing quantities, sizes, conditions, ratios, ranges, etc. used in the specification and claims may be increased or decreased by about 5% to achieve satisfactory results. In addition, all ranges described herein may be reduced to any sub-range or portion of a range, or to any value within a range, without departing from the invention.

The term "a" or "an" object in the context of the present description refers to one or more of these objects. As such, the terms "a" (or "an"), "one or more" and "at least one" may be used interchangeably herein.

The use of the terms "including", "comprising" or "having" and their variants in this document means the coverage of the elements listed hereinafter and their equivalents, as well as additional elements. Accordingly, the terms "including", "comprising" or "having" and variations thereof may be used interchangeably herein.

It should be appreciated that the term “remedy” as used in this document is to be construed as broadly as possible in accordance with 35 U.S.C. (United States Code), Section 112 (f). Accordingly, a claim that includes the term "agent" is intended to encompass all structures, materials, or acts set forth herein and all their equivalents. In addition, structures, materials, or acts and their equivalents shall include all those structures, materials, or acts described in the Summary of the Invention, Brief Description of the Drawings, Detailed Description, Abstract and Claims sections.

The Summary of the Invention in the Summary of the Invention section is not intended and should not be construed as representing the full scope and scope of the present invention. Moreover, references made herein to “the present invention” or aspects thereof are to be understood to mean certain embodiments of the present invention and are not necessarily to be construed as limiting all embodiments to the specific description. It will be appreciated that other embodiments are possible using, individually or in combination, one or more of the features set forth above or described below. For example, it is contemplated that various features and devices shown and / or described in relation to one embodiment or drawing may be combined or replaced by functions or devices of other embodiments or figures, regardless of whether such combination or replacement is specifically shown. or described here. The present invention is set forth in varying levels of detail in the Summary of the Invention section, as well as in the accompanying drawings and in the Detailed Description, and no limitation on the scope of the present invention is intended to include or exclude elements or components. Additional aspects of the present invention will become more apparent from the Detailed Description, particularly when taken in conjunction with the drawings.

Brief Description of Drawings

The accompanying drawings, which are included in this description and form part of the description, illustrate embodiments of the invention, and together with the above section of the Summary of the invention and the Detailed description below, serve to explain the principles of these embodiments. In some cases, details that are not necessary to understand the disclosure, or that make it difficult to understand other details, may be omitted. Of course, it should be appreciated that the present invention is not necessarily limited to the specific embodiments illustrated herein. In addition, it should be appreciated that the drawings are not necessarily drawn to scale.

1 is a schematic block diagram of a decorating device depicting one embodiment of the present invention and also illustrating a metal container, end closure, and crown lid decorated with the decorating device of the present invention;

FIG. 1A is a schematic block diagram of a decorating device including blanket supports of variable length such that the relative speed of a segment of a blanket can vary as the blanket support rotates;

FIG. 1B is a schematic block diagram of a decorating device in which blanket segments are coupled to a blanket support that is pivotable relative to a blanket wheel; FIG.

FIG. 1C is a schematic block diagram of a decorating device including two feed units aligned with a blanket wheel having blanket segments mounted thereon;

FIG. 2A is a schematic block diagram of a digital printing unit including an inkjet printhead according to one embodiment of the present invention;

FIG. 2B is a schematic block diagram of a digital printing unit of one embodiment of the present invention that includes an electrophotographic system for generating a decoration that is transferred to a printing blanket of a decorating device;

FIG. 3 is another schematic block diagram of another embodiment of a decorating device of the present invention including a continuous blanket;

FIG. 3A is a partial view of the decorator shown in FIG. 3 illustrating an inner take-up roller in one position of use engaging the continuous blanket;

FIG. 3B is another partial view of the decorating device of FIG. 3 showing a rear side idler roller engaging the continuous blanket;

FIG. 3C is another partial view of the decorator of FIG. 3, the tensioning guide 58 is illustrated after being moved relative to the continuous blanket;

Fig. 3D is a partial view of a tensioner with a pair of rollers interacting with a continuous blanket;

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

FIG. 4 is another schematic block diagram of another embodiment of a decorator of the present invention that includes a multi-mandrel feed unit;

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

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

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

Similar components and / or features may have the same reference number. Components of the same type can be distinguished by the letter following the reference number. If only the reference number is used, the description applies to any of the like components having the same reference number.

To aid in the understanding of the present invention, the following list of components and corresponding numbering found in the drawings are provided herein:

Item number Component

2 Decorator

4 Digital printing unit

5 Temperature control device

6 Blanket

6A Blanket segments

6B Continuous blanket

6C Continuous blanket

7 Decoration on the blanket

8 Feed unit

9 Stations

10 Conveyor

11 Mandrels

12 Control system

13 Conveyor

14 Cleaning system

15 Distance between adjacent blanket segments

16 Curing unit

17 Curing unit

18 Blanket wheel or blanket cylinder

20 Blanket support

21 Distance between blanket wheel and blanket segment

22 Metal container

23 First decoration

24 Outside surface of metal container

25 Image transfer position

26 Upstream equipment

27 Surface treatment unit

28 Decorated metal container

29 Swivel joint

30 Decoration on metal containers

31 Second pivot joint

32 Downstream equipment

33 Third pivot joint

34 End closure

36 Crown cover

37 First section of the blanket support

38 Second blanket support section

39 Third section of the blanket support

40 Electrophotographic system

41 inkjet print head

42 Explorer

43 Printing ink

44 Charging element

45 Nozzle

46 Exposure element

47 Light emitter

48 Developing unit

49 Movie

50 Charging element

51 Ink source

52 Toner

53 Aperture

54 Internal idler roller

55 Light

56 Rear side tension roller

58 Guide tensioner

60 Rotating tensioner device

60A Rotary tensioner with a pair of rollers

61 P Tensioner rollers with a pair of rollers

62 Pressure roller

63 Coupling device

64 Servo

65 Blanket width

66 Blanket segment

67 Longitudinal edge of the blanket segment

68 Bus

70 Central processing unit CPU

72 Input devices

74 Output devices

76 Storage devices

78 Device for reading machine-readable media

80 Communication system

82 Working memory

84 Additional acceleration of data processing

86 Database

88 Network

90 Database

92 Operating system

94 Other code

Detailed description

The present invention has significant advantages in a wide range of areas of activity. It is the applicant's intent that this specification and the appended claims be expanded in accordance with the scope and spirit of the disclosed invention, although the disclosure may appear limiting due to the use of language that requires reference to specific disclosed examples. To familiarize those skilled in the art most closely related to the present invention, a preferred embodiment that illustrates the best mode currently contemplated for practicing the invention is described herein with reference to the accompanying drawings, which form part of the description. An illustrative embodiment is described in detail without attempting to describe all the various forms and modifications in which the invention may be embodied. As such, the embodiments described herein are illustrative and, as will become apparent to those skilled in the art, may be modified in a variety of ways within the scope and spirit of the invention.

FIG. 1 is a schematic block diagram of a decorator 2 of the present invention. The decorator 2 generally comprises at least one digital printing unit 4, a blanket 6, a feeding unit 8, conveyors 10, 13 and a control system 12. In one embodiment, the blanket 6 comprises a plurality of blanket segments 6A. Decorator 2 may optionally include one or more of a cleaning system 14 and a curing or drying unit 16, 17. If necessary, the decorator 2 may include at least one temperature control device 5.

The digital printing units 4 are in a predetermined alignment position with respect to the blanket 6. The digital printing units 4 form the decoration 7 on the blanket 6. In one embodiment, the decorator 2 includes one to four blocks 4A, 4B, 4C, 4D digital printing. However, it should be appreciated that any number of digital printing units 4 may be used with the decorators 2 of the embodiments of the present invention. For example, in one embodiment, decorator 2 includes one to ten different digital printing units 4.

In one embodiment of the invention, the digital printing unit 4 contacts the blanket 6 to form a character or decoration 7 on the blanket 6. Alternatively, in another embodiment, the digital printing units 4 do not contact the blanket 6, but instead are applied sign or decoration 7 on a blanket without contact. In one embodiment, the digital printing unit 4 may generate decoration with a resolution of at least 1600 by 1600 dpi. Thus, the decorations 7 formed on the blanket 6 are considered high definition images.

In one embodiment of the invention, the digital printing units 4 form the decoration 7 on the blanket 6 by spraying, inkjetting, or otherwise transferring ink onto the blanket 6. In one embodiment, one or more digital printing units 4 comprise an inkjet printer or an inkjet printer a head 41 (such as illustrated in FIG. 2A). In another embodiment, the digital printing units 4 form the decoration 7 on the blanket 6 by transferring toner to the blanket. More specifically, in one embodiment, the digital printing unit 4 includes an electrophotographic system 40 (generally illustrated in FIG. 2B) that transfers toner material 52 onto a blanket. One of the digital printing units 4 can be an inkjet printer and the other digital printing unit 4 can be an electrophotographic system 40. The order and relative positions of the digital printing units 4 with respect to the blanket wheel 18 can be changed.

In one embodiment of the invention, each of the digital printing units 4A, 4B, 4C, 4D transfers a decoration material of the same color or type to the blanket 6. Thus, the first digital printing unit 4A transfers the first decoration material to the blanket 6. Similarly, the second the digital printing unit 4B transfers the second decoration material, the third digital printing unit 4C transfers the third decoration material, and the fourth digital printing unit 4D transfers the fourth decoration material onto the blanket 6. The decoration material carried by each of the digital printing units is one of ink and toner numbers. The decoration 7 formed on the blanket 6 may contain one or more elements from among the first, second, third and fourth ink and / or toner. The decoration material from each digital printing unit 4 can be applied to different parts of the blanket 6 to form a single decorative design 7. In addition, the decoration material from two or more digital printing units 4 can at least partially overlap or overlap each other, to shape the decoration 7.

Alternatively, in another embodiment of the invention, two or more digital printing units 4 may transmit the same color of decoration material to the blanket 6. The first digital printing unit 4A may form part of a single decoration 7 of the first color. The second digital printing unit 4B may form a second portion of a single decoration 7 of one or more colors from among the first and second colors. In one embodiment, by dividing the decoration 7 generation between the two digital printing units 4A, 4B, the decorator 2 of the present invention can operate at a faster speed than a decorator with a single digital printing unit used to generate the decoration. More specifically, the blanket 6 can move past the digital printing units 4A, 4B at a faster speed than if one digital printing unit 6 was used to form the entire decoration 7.

In another embodiment of the invention, one or more digital printing units 4 are capable of transmitting a plurality of colors or types of decoration material to the blanket 6. For example, in one embodiment, at least one of the digital printing units 4 can transfer decoration material of at least one colors from cyan, magenta, yellow and black (or "key") color on a blanket 6 to form a decorative design 7.

In one embodiment, each digital printing unit 4 forms a complete decoration 7 on the blanket 6. In another embodiment, each digital printing unit 4 may form part of the decoration 7 on the blanket 6. Accordingly, the first digital printing unit 4A carries the decoration material onto the blanket 6 to form the first decoration part 7. The second digital printing unit 4B transfers additional decoration material to the blanket 6 to form the second decoration part 7. The third and fourth digital printing units 4C, 4D may form the third and fourth parts decoration 7. Each part of the decoration 7 may contain one or more colors or types of decoration material.

As shown in FIG. 2A, in one embodiment, at least one of the digital printing units 4 is an ink jet printhead 41. An inkjet printhead 41 typically includes a reservoir or source 51 of ink 43 and nozzles 45. The nozzles 45 are configured to spray ink 43 onto the blanket 6. In one embodiment, the inkjet printhead 41 can deliver up to 774 million drops of ink 43 per second. In another embodiment, the inkjet printhead 41 includes five color channels. In yet another embodiment, the inkjet printhead 41 includes 10 rows of nozzles 45 with up to 70,400 nozzles per row for printing inks 43 in five colors at resolutions up to 1600 dpi.

Any suitable ink 43 may be used with the inkjet printhead 41 of the present invention. In one embodiment, the inkjet printhead 41 may use nanoparticle ink to form a predetermined image or characters on the outer surface 24 of the metal container 22. In another embodiment, the inkjet printhead 41 may use ink 43 with a particle size not exceeding about 500 nm. In one embodiment, the ink 43 comprises a light curable ink, such as, but not limited to, an ultraviolet (UV, UV) curable ink. In another embodiment, the ink 43 comprises a water-based ink that is heat-cured. In yet another embodiment, the ink 43 comprises an oil-based ink that is heat-cured. In one embodiment, the oil based ink comprises a mineral oil ink.

If necessary, the inkjet printhead 41 is configured to change the viscosity of the ink 43. More specifically, the inkjet printhead 41 can adjust the viscosity of the ink 43 through one or more actions of changing the temperature of the ink 43 and activating the initiators in the inkjet. ink 43. In one embodiment, changing or adjusting the viscosity of the ink 43 changes the size of the dots or droplets of the ink 43 forming the decoration 7 on the blanket 6. Thus, the ink from the different inkjet printheads 41 can be transferred to the blanket 6 in close proximity to each other to form a decorative design 7, while the paints are in a wet or uncured state. Additionally or alternatively, changing the viscosity of the printing ink 43 prevents inadvertent or unwanted movement of dots or ink droplets 43 on the blanket 6. Accordingly, a plurality of printing inks from different inkjet printheads 41 can be transferred to the blanket 6 without curing before transferring additional inks to the blanket 6. offset blanket. By adjusting the viscosity of the ink, the inkjet printhead 41 can “pre-pin” or “partially cure” the ink 43 onto the blanket. More specifically, in one embodiment, the viscosity of the ink can be adjusted to at least partially cure or dry the ink before or after contact with the blanket 6.

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

In one embodiment of the invention, at least one light emitter 47 interacts with an ink jet printhead 41. Light emitter 47 is configured to emit light 55. Light 55 has a predetermined wavelength selected to activate one or more initiators in ink 43. When activated by contact with light 55, initiators change the viscosity of ink 43. In one embodiment, light 55 represents ultraviolet light.

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

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

If necessary, the light emitter 47C may be oriented to direct light 55C, which illuminates the ink droplets 43 emitted from the nozzles 45. The light 55C may be oriented to illuminate the ink droplets 43 before the ink reaches blanket 6. Thus, the light emitter 47C can change the viscosity of the ink droplets 43 before the printing ink contacts the blanket 6.

Additionally or alternatively, in one embodiment, the light emitter 47D is oriented to direct light 55D towards the blanket 6. The light 55D may have a predetermined wavelength to activate initiators in the ink 43 when the ink is positioned on the blanket 6 Accordingly, the light emitter 47D is configured to change the viscosity of the ink positioned on the blanket.

In one embodiment of the invention, at least one of the digital printing units 4 comprises an inkjet printing unit 41. Suitable inkjet printheads 41 can be obtained from a variety of suppliers including, but not limited to, Xaar, Konica Minolta, FujiFilm, Kyocera, Tonejet, and Memjet inks.

As shown in FIG. 2B, in one embodiment of the invention, one or more digital printing units 4 may comprise an electrophotographic system 40. The electrophotographic system 40 may typically include one or more conductors 42 (also called an "Electrophotographic plate"), an "emitter" or a charging element 44. exposure element 46 and developing unit 48. In one embodiment, the electrophotographic system 40 further includes one or more of a cleaning element 14A and a charging element 50. Electrophotographic systems and toners used therewith are generally described in the following U.S. patents: International Patent Application Publication No. 2006/0068313, US Patent No. 4,743,926, US Patent. No. 5,018,640, US Patent. No. 5,065,183, US Patent. No. 5,750,303, US Patent. No. 6,818,369, US Patent No. 7,666,564 and US Patent No. 7,939,235, each of which is fully incorporated herein by reference.

The guide 42 is positioned in a predetermined alignment with the path of the decorating blanket 6. In one embodiment, the guide 42 rotates in contact with the outer surface of the blanket 6. In another embodiment, the guide 42 rotates in close proximity to the outer surface of the blanket without contacting with a blanket 6. Regardless of this, the conductor 42 is oriented to transfer the toner 52 to the blanket 6. In one embodiment, the conductor 42 has a shape that is generally cylindrical in shape. In another embodiment, conductor 42 is in the form of a loop or belt, which may be round or serpentine. The loop of the conductor 42 may extend around one or more rollers and tensioning mechanisms such as described herein.

In one embodiment, conductor 42 includes a material that is photoconductive. More specifically, in one embodiment, the surface of the conductor 42 is conductive when exposed to light. The surface becomes non-conductive in the absence of light. 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: silicon, selenium, cadmium sulfide, zinc oxide, and the like. In another embodiment, conductor 42 includes at least one layer of organic material. If necessary, the organic photoconductive material includes one or more of polyvinylcarbazole, phthalocyanine, and the like.

During operation of the device, a charging element 44, or "source" (emitter), supplies an electrical charge to the conductor 42. In one embodiment, the charging element 44 produces a corona discharge to electrically charge the conductor 42. A decoration is then formed on the outer surface of the conductor 42. In one embodiment, charging element 44 has a generally cylindrical shape. In another embodiment, the charging cell 44 contacts the conductor 42 when the charging cell electrically charges the conductor.

The formation of decoration involves the exposure of selected parts of the conductor to light. More specifically, the exposure element 46 selectively exposes portions of the conductor 42 to light. The exposure element 46 can direct light that will selectively fall on predetermined portions of the outer surface of the conductor 42 to mimic the shape of the decoration. The portions of the conductor 42 exposed to light by the exposure element 46 are neutralized when the charge provided by the charging element 44 is removed by the conductive surface of the conductor. Other parts of conductor 42 that are not exposed to light remain charged. The remaining charged regions of conductor 42 form a hidden decoration on conductor 42. Accordingly, exposure element 46 can discharge selected portions of conductor 42. In one embodiment, the hidden decoration is electrostatic.

In one embodiment, the decoration formed by the exposure element 46 is received from the control system 12 of the decoration device 2. More specifically, in one embodiment, the control system 12 sends a signal to the exposure element 46 to expose predetermined portions of the conductor 42 to form a hidden decoration. registration. In another embodiment, exposure element 46 comprises a laser or other device that generates light.

The developing unit 48 converts the hidden decoration into a decoration 7 that is visible. In one embodiment, the developing unit 48 includes a toner 52. The toner 52 is attracted to the charged areas of the hidden decoration formed by the exposure element 46. Thus, the toner 52 forms the decoration 7 that is visible on the conductor 42. If necessary, the developing unit 48 includes a roller 49 that transfers the toner 52 to the conductor 42. In another embodiment, the developing unit 48 includes a blade for adjusting the amount or thickness of the toner 52 on the roller 49. If necessary, the toner 52 on the roller 49 is limited to the blade to a thickness of more than about 0.3 mm.

In one embodiment, the toner 52 contains charged particles that adhere to the hidden decoration. In one embodiment, the toner 52 may be electrically charged. In another embodiment, the toner 52 has an electrical charge with polarity opposite to that of the conductor 42 generated by the charging element 44. If desired, the developing unit 48 may use liquid toner or dry toner to develop decoration. In one embodiment, the dry toner uses only toner 52. In another embodiment, the dry toner includes a carrier that transfers the toner to the conductor 42. In one embodiment, the carrier contains particles. The carrier particles can be larger than the toner particles 52.

The toner carrier 52 may contain one or more of iron powder, ferrite, magnetite, and glass beads. These carriers can be resin coated. The resin can include, but is not limited to, polycarbonate fluorides, polyvinyl chlorides, polyvinylidene chloride, phenolic resins, polyvinyl acetal, and silicone resins. In one embodiment, the blending ratio of toner to carrier is from about 1.5 to about 10.0 parts by weight of toner 52 to 100 parts by weight of 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, the toner material 52 includes at least one of a binder resin, a colorant, a polar resin, and a release agent. In one embodiment, the content of each color is typically from about 0.1 to 50 parts by weight based on 100 parts by weight of the binder resin. If necessary, the toner material 52 may include a polymer such as, but not limited to, styrene acrylate copolymer, polyester resin, and styrene butadiene copolymer.

In one embodiment, an external additive is added to the toner 52. The external additive may include at least one inorganic or organic particulate component. External additives can be surface treated to improve hydrophobic properties and prevent deterioration of the flow and charging properties of the toner 52 in a high humidity environment. Specific preferred examples of surface treatment agents include, but are not limited to, coupling agents such as silane coupling agents; titanate binders and aluminum binders; silicone oil; higher aliphatic acids; and fluorine compounds.

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, silicon dioxide, alumina, titanium oxide, barium titanate, magnesium titanate, calcium titanate, strontium titanate, zinc oxide, tin oxide, silica sand, clay, mica, lime-sand mixture, 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 can contain organic particles such as, but not limited to, one or more copolymers of styrene, methacrylic acid esters and acrylic acid esters, which can be prepared by a soap-free emulsion polymerization method, a suspension polymerization method, or a dispersion polymerization method as well as polycondensation thermosetting resins such as silicone resins, benzoguanamine resins and nylon.

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

The toner material 52 can be formed from a variety of particle sizes. In one embodiment, the toner has an average particle size of less than about 16 micrometers. In another embodiment, the average toner particle size is less than about 10 micrometers. The particle size of the toner can be greater than about 6 micrometers. If necessary, the particle size of the toner 52 is from about 6 micrometers to about 18 micrometers.

In one embodiment, the electrophotographic system 40 can transfer one or more colors of the toner material 52 to the blanket 6. For example, in one embodiment, the electrophotographic system 40 can transfer the toner material 52 from one to four colors. In one embodiment, the toner material 52 contains one or more dyes of cyan dye, magenta dye, yellow dye, and black dye. If necessary, each color of the 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. Thus, the electrophotographic system 40 can form a decoration 7 containing a plurality of different colors of the toner material 52.

As the conductor 42 rotates adjacent to the blanket 6, toner 52 is transferred from the conductor to the blanket. In one embodiment of the invention, charging element 50, optionally provided, generates a charge that attracts toner 52 from conductor 42 to blanket 6. In one embodiment, charging element 50 generates a corona discharge to attract toner 52. Toner 52 forms decoration 7 on blanket 6. The decoration 7 can then be transferred to the outer surface 24 of the container, as described herein.

If necessary, the conductor 42 is subsequently cleaned by the cleaning system 14A. More specifically, the cleaning system 14A removes any toner particles 52 that have not been transferred to the blanket 6. In one embodiment, the cleaning system 14A has a shape that is generally cylindrical. Additionally, in one embodiment, the cleaning system 14A may also discharge the conductor 42. For example, in one embodiment, the purification system 14A generates light to expose the conductor 42 to light across its entire width. Thus, any remaining charge on conductor 42 is discharged by the cleaning system 14A, with the result that conductor 42 can subsequently receive new charge from charging cell 44.

Returning again to FIG. 1, the decorations 7 formed by the digital printing units 4 may include any combination of letters, numbers, symbols and images arranged in any order or orientation, as well as any size. Decorations are made from a decorating material (such as printing ink or toner) and can be one color or multiple colors. In addition, each decoration can be unique. For example, decoration 7A may differ from one or more decorations 7B, 7C. Thus, it is economically feasible with the decorating device 2 of the present invention to produce small batches of decorated metal containers 28 with various designs 30 on them.

The blanket 6 of the decorating device 2 can be of any size or shape. In one embodiment of the present invention shown in FIG. 1, the blanket 6 comprises a plurality of discrete blanket segments 6A interconnected by a support member such as a blanket wheel 18. However, in another embodiment, one blanket 6 may be placed on a blanket wheel 18. In another embodiment, the blanket 6 may comprise a single sleeve or cylinder that wraps around the circumference of the blanket wheel 18. In addition, the decorator 2 can use a continuous blanket that is not circular. If necessary, each blanket segment 6A has a length that is not less than the circumference of the metal container 22.

The blankets 6 of the embodiments of the present invention may be formed from a material selected for receiving and holding a decoration material from the digital printing units 4. In one embodiment, the blankets 6 comprise one or more faces, a first fabric layer, a compressible layer, and a second fabric layer as described in Offset Printing Blankets (hereinafter “Offset Printing”) available at http: / /www.offsetprintingtechnology.com/sub-categories/blanket-for-Offset-Printing/ (last visited April 7, 2016), which is incorporated herein by reference in its entirety. The face can contain a relatively thin rubber material such as nitrile butadiene rubber (NBR). As will be understood by one skilled in the art, NBR is a family of unsaturated copolymers of 2-propenenitrile and various monomers of butadiene (1,2-butadiene and 1,3-butadiene). NBR is also known as Buna-N, Perbunan, acrylonitrile butadiene rubber, Nipol (nipol, styrene butadiene rubber), Krynac and Europrene.

In another embodiment of the invention, the blankets 6 may contain a photopolymer material or a compound containing an at least partially saturated polymethylene chain. Suitable materials for blanket 6 are described in US Patent Application Publication No. 2015/0217559, which is incorporated herein by reference in its entirety.

When the device is in operation, the blanket 6 rotates in the first direction. The digital printing units 4 transfer or spray decorating material onto a portion of the outer surface of the blanket 6 to form the decorations 7. In one embodiment, the blanket 6 moves continuously at a predetermined speed. In another embodiment, the blanket 6 is indexed such that the blanket 6 is stopped for a predetermined period of time near one or more digital printing units 4. Thus, the blanket 6 can be substantially stationary when the digital printing unit 4 forms the decoration 7 on the blanket 6. Regardless of this, in another embodiment, the movement of the blanket 6 relative to the digital printing units 4 is carried out at a speed selected by the system 12 management. Accordingly, the control system 12 can control the speed and position of the decorations 7 generated by the digital printing units 4 and the movement of the blanket 6 so that the decorations are subsequently transferred to the metal container 22. In one embodiment, the control system 12 sends a signal to an actuator or drive unit for the blanket wheel 18 for controlling the speed of movement of the blanket wheel 18.

If necessary, decorations 7 can be cured (or at least partially cured) using one or more curing blocks 16. In one embodiment, the curing unit 16 interacts with each of the digital printing units 4. Thus, the decoration material injected (or carried) by each of the digital printing units 4 is at least partially cured or fixed on the blanket before the subsequent digital printing unit 4 transfers additional decoration material to the blanket 6 to form a decorative Decorating 7. In another embodiment, only one curing unit 16D cures all decorating materials applied by the digital printing units 4A, 4B, 4C, and 4D. The curing unit 16D may be positioned between the final digital printing unit 4D and the image transfer portion 25 of the decorating device. In one embodiment, the curing units 16 generate light at a wavelength selected for at least partially curing or fixing the decoration material carried by the digital printing units 4. In one embodiment, the curing units 16 comprise an ultraviolet or ultraviolet light-emitting diode (UV LED) lamp for curing. In another embodiment, the curing blocks 16 generate heat energy to cure the decoration material. If necessary, the curing units 16 can generate infrared light. In one embodiment, curing unit 16 is adapted to cure toner 52. In another embodiment, curing unit 16 is adapted to cure ink 43. If desired, curing unit 16 can cure both ink 43 and toner 52.

The feeding unit 8 moves the metal containers 22 to a predetermined position with respect to the blanket 6. Then, a portion 24 of the outer surface of the metal containers 22 rotates in contact with the outer surface of the blanket 6. Thus, a decoration material such as printing ink or toner on the outer surface the blanket forming the decorative design 7 is transferred from the blanket 6 to a metal container.

In one embodiment, the feed unit 8 can rotate the metal containers 22 so that the outer surface 24 is in a predetermined position relative to the decorator 2. More specifically, in one embodiment, the feed unit 8 can detect an alignment mark on the metal containers 22. The block 8 can then rotate the metal containers 22 so that the alignment mark is at a predetermined alignment level with the blanket 6. Thus, the outer surface 24 of the container will be in a predetermined alignment position with decorator 2. If necessary, the sensor detects the alignment mark. In one embodiment, the alignment mark is a character printed on the metal container 22. In another embodiment, the alignment mark is a protrusion, an elongated portion, or a recess formed on the metal container. An example of a delivery device that can be used with the decorating device 2 of the present invention is described in US Pat. No. 9,027,733, which is hereby incorporated by reference in its entirety. In one embodiment, control system 12 receives alignment mark information. The control system 12 can then determine if the metal container is in a predetermined alignment position. If the metal container is not in the predetermined alignment position, the control system 12 can send a signal to the feed unit 8 to rotate the metal container to the predetermined position.

In one embodiment of the present invention, the supply unit 8 operates at a different cycle rate (or speed) than the rotational speed of the blanket 6. More specifically, in a decorating device 2A with multiple digital printing units 4 and / or segmented blanket 6A (as illustrated in one embodiment of the present invention in Fig. 1) the processing speed of the metal containers 22 may be different from the printing speed of the digital printing units 4. Thus, decorator 2 can decorate metal containers 22 with unique decorations 7 formed using digital printing technology, including an inkjet printer 41 or an electrophotographic system 40, at a faster rate than prior art inkjet container decorating systems or electrophotographic decorating systems.

In one embodiment, the individual blanket segments 6A are connected to a blanket wheel 18, whereby the blanket segments 6A can vary speed to match the rotational speed of the metal container 22 in the feed unit 8. Thus, the segments 6A of the blanket can be accelerated or decelerated to match the rotational speed of the outer surface 24 of the container to transfer the image 7 to the portion 24 of the outer surface of the container. In one embodiment, the blanket segments 6A are removably connected to the blanket wheel 18. If necessary, the blanket segments 6A are detached from the blanket wheel 18 after transferring the decorating material to the metal container 22. In one embodiment, the digital printing units 4 transfer the decorating material to the blanket segments 6A when these blanket segments are separated from the blanket wheel 18 ... In another embodiment, there are more blanket segments 6A than blanket stations on blanket wheel 18. The segments 6A of the blanket can run in two or more paths through the decorator 2 when they are separated from the blanket wheel 18. The first group of segments 6A of the blanket can be moved along the first path to receive decoration material from the first group of blocks 4 of digital printing. The second set of blanket segments 6A may follow the second path and receive decoration material from the second set of digital printing units. In one embodiment, upon receipt of the decorating material from the digital printing unit, the blanket segments 6A are returned to the blanket wheel 18. Optionally, in one embodiment, each blanket segment 6A is connected to the blanket wheel 18 during transfer of decorating material to the metal container 22. Thus, after the image 7 is formed on the blanket segment 6A, the blanket segment 6A can be accelerated or decelerate to match the speed of the portion 24 of the outer surface of the metal container 22.

In another embodiment of the present invention, each individual blanket segment 6A is disposed on a mandrel connected to a blanket wheel 18. Each mandrel can rotate independently about an axis of the mandrel that is substantially parallel to the axis of the blanket wheel 18. Thus, each individual blanket segment 6A can rotate on a mandrel interacting with it at a first speed when the digital printing units 4 form a decoration 7 on the blanket segment 6A. In addition, each individual blanket segment 6A can rotate on an associated mandrel at a second speed during the transfer of the decoration 7 to the metal container 22 positioned by the feed unit 8. The second rotational speed of the individual blanket segment 6A can be selected to match the rotational speed of the metal container 22.

In another embodiment, the individual blanket segments 6A are separated by a distance 15 that can vary. Accordingly, two adjacent blanket segments 6A may be separated by a distance 15A adjacent to one or more digital printing units 4. Adjacent blanket segments 6A may be separated by a second distance 15B in the vicinity of the feed unit 8. In an embodiment, the first distance 15A is less than the second distance 15B. If desired, the first distance 15A can be less than about 1 inch, whereby the blanket segments 6A pass by the digital printing units 4 substantially continuously. Thus, the segments 6A of the blanket have a first line speed near the digital printing units 4 and a second line speed near the supply unit 8. In one embodiment, the first line speed is lower than the second line speed. Accordingly, the segments 6A of the blanket can move relatively slowly in the vicinity of the digital printing units 4. Continuing with this example, the blanket segments 6A move faster around the feed unit 8 and metal containers 22. Thus, the blanket segments 6A can be accelerated to match the radial speed of the outer surface portion 24 of the metal canister 22 in the feed unit 8.

In one embodiment, the blanket segments 6A are interconnected with the blanket wheel 18, whereby the blanket segments 6A can move independently of the continuous rotation of the blanket wheel 18. In another embodiment, the segments of the blanket are connected to the blanket wheel 18 by one or more hinges, rollers, cams and springs. Thus, the segment 6A of the blanket can be held in the first position and accelerated in another position. By means of a delay and predetermined positions, the blanket segment 6A can remain for a longer period of time in the vicinity of one or more decoration elements, such as one or more of the digital printing unit 4, the fixing unit 16, and the feeding unit 8. the time of transferring the image to the metal container 22 and in the cleaning system 14.

As shown in FIG. 1A, in one embodiment of the present invention, the blanket segments 6A are connected to the blanket wheel 18 by blanket supports 20A. Each segment 6A of the blanket is connected to an end of the support 20A of the blanket extending from the wheel of the blanket. The blanket supports 20A position the blanket segments 6A at a predetermined distance 21 from the blanket wheel 18. If necessary, the blanket supports 20A project radially from the blanket wheel 18. In one embodiment, the blanket supports 20A are oriented approximately perpendicular to the axis about which the blanket wheel 18 rotates.

The supports 20A of the blanket can change the positions of the interacting segments 6A of the blanket with respect to the wheel 18 of the blanket. In one embodiment, the blanket supports 20A are capable of varying the distance 21 between the blanket wheel 18 and the blanket segments 6A. Accordingly, the blanket supports 20A can increase and decrease the distance 21 between the blanket wheel and the blanket segments as the blanket wheel 18 rotates. Thus, each segment 6A of the blanket can have an elliptical path (or orbit) around the wheel 18 of the blanket. In addition, the relative speed of the blanket segments 6A may vary with respect to the digital printing units 4 and the transfer position 25. In addition, the blanket webs 6A may have a first spacing 15A in a first decorating position 2A and a second spacing 15B in a second decorating position 2A. Optionally, adjacent to the digital printing units 4, the first spacing 15A is smaller than the second spacing 15B near the image transfer position 25.

In one embodiment of the invention, the segments 6A of the blanket are at a first distance 21A from the blanket wheel 18, in the vicinity of the transfer position 25. The segments 6A of the blanket are at a second distance 21B from the blanket wheel 18, in the vicinity of the digital printing units 4. In one embodiment, the first distance 21A is greater than the second distance 21B. Accordingly, in one embodiment, the blankets 6A move faster relative to the metal containers 22 decorated at the transfer position 25 and slower relative to the digital printing units 4 during the transfer of the decoration material to the blankets 6A.

The blanket supports 20A can vary the distance 21 between the blanket wheel 18 and the blanket segments 6A in a variety of ways. In one embodiment, the blanket supports 20A can be at least partially retractable into the blanket wheel 18. For example, in one embodiment, the blanket wheel 18 includes a recess or hole (not shown for clarity) interacting with each blanket support 20A. A portion of the blanket supports 20A can selectively retract or exit from the associated holes of the blanket wheel 18. Thus, the distance 21 between the blanket segment 6A and the blanket wheel 18 can be adjusted while the blanket wheel is rotating.

The segments 6A of the blanket may have a curved or arcuate shape. Optionally, in one embodiment, the blanket support 20A is configured to adjust the shape of the blanket segment 6A when the blanket segment 6A rotates around the blanket wheel 18. For example, when the blanket support 20A extends the blanket segment 6A away from the blanket wheel 18, for example, in the vicinity of the transfer position 25, the blanket support can reshape the blanket segment 6A to become flatter. Additionally or alternatively, when the blanket support moves the blanket segment 6A closer to the blanket wheel, the blanket support can adjust the shape of the blanket segment to be more arcuate and less flat.

Additionally or alternatively, in one embodiment of the invention, the blanket supports 20A may be of adjustable length. For example, blanket supports 20A may include at least two sections 37-39. The sections can be telescopic, whereby the length of each blanket support 20A can be adjusted. In one embodiment, the at least two sections comprise a first section 37 and a second section 38. The second section 38 may at least partially extend into the first section 37. Optionally, the blanket supports 20A may include a third section 39. The second section 38 can be installed at least partially in the third section 39, and the third section 39 can protrude from the first section 37 or retract into it.

As shown in FIG. 1B, in another embodiment of the present invention, the blanket supports 20B coupled to the blanket wheel 18 are pivotable relative to the blanket wheel. Thus, the blanket support 20B can move the blanket 6A at different speeds relative to the digital printing unit 4 as compared to the metal container 22 to be decorated at the transfer position 25. In one embodiment, the blanket support 20B pivots or moves the blanket segment 6A relative to the digital printing unit 4 at a first speed. The blanket support 20B can move the blanket segment 6A relative to the metal container 22 at the second speed transfer position 25. In one embodiment, the first speed is less than the second speed. Thus, the blanket support 20B can move the blanket segment 6A more slowly compared to the digital printing units 4 and faster relative to the metal container 22 during the transfer of decoration at the transfer position 25.

In one embodiment, the blanket supports 20B may be pivotally coupled to the blanket wheel 18 via a pivot connection 29. Thus, the blanket supports 20B can pivot at different angles relative to the blanket wheel. For example, the blanket support 20B of the image 7B is shown rotated about the pivot 29 such that the image 7B is adjacent to the blanket support of the image 7A. Thus, the segment of the blanket with the image 7B is separated from the segment of the blanket with the image 7A by a distance of 15B. The distance 15B between the blanket segments is less than the distance 15A when the blanket supports 20B project substantially radially (or do not pivot) relative to the blanket wheel, for example, in the vicinity of the digital printing units 4. If necessary, the supports 20B of the blanket can be rotated at an angle of from about -45 ° to about + 45 ° with respect to the radius of the cylinder of the blanket.

In one embodiment, the blanket segments 6A are connected to the outside of the blanket support 20B by a second pivot 31. Accordingly, the outer surface of the blanket segments 6A can rotate to a predetermined orientation as the blanket wheel 18 rotates. In one embodiment, the blanket segment 6A is rotatable about the second pivot 31 relative to the blanket support 20B, so that the outer surface of the blanket segment is in a predetermined orientation with respect to one or more of the cleaning system 14, digital printing unit 4 , a curing unit 16, a feeding unit 8, a cleaning system 14, and a temperature control device 5.

In one embodiment, the blanket supports 20B include two or more sections 37, 38 that are pivotally coupled to the supports. More specifically, the blanket support 20B may include a first section 37 coupled to a blanket wheel 18. The second section 38 of the blanket support 20B is connected to the blanket segment 6A. If necessary, the first and second sections 37, 38 of the blanket support 20B are pivotally connected to each other. For example, the first section 37 may be connected to the second section 38 via a third pivot 33. If necessary, the blanket supports 20B are configured to vary the distance separating the blanket segments 6A from the blanket cylinder 18 in a similar manner to the blanket supports 20A for the blanket described with reference to FIG. 1A, or in the same way.

Returning again to FIG. 1, in one embodiment of the present invention, the feed unit 8A has a shape that is generally cylindrical. If desired, the supply unit 8A may include a plurality of stations 9 for receiving and supporting the metal containers 22 in a predetermined position with respect to the blanket 6. In one embodiment, the supply unit 8 can rotate the metal container 22, whereby the outer surface 24 moves with a speed substantially equal to the rotational speed of the blanket 6. Thus, the dynamic effect on the blanket 6 is minimized.

In one embodiment of the invention, the supply unit 8A includes mandrels 11 for supporting and / or rotating metal containers 22. If necessary, the mandrels 11 can cooperate with stations 9. In one embodiment, each mandrel 11 can rotate about an axis substantially parallel the axis of rotation of the feed unit 8A. In one embodiment, the mandrel 11 with the metal container 22 thereon can be rotated such that a predetermined portion of the outer surface of the metal container 22 contacts the blanket 6A. Optionally, a servo unit or other mechanical or electrical means is configured to rotate the mandrels 11. In one embodiment, the servo motor interacts with each of the mandrels. In another embodiment, the servo is controlled by a signal from the control system 12. In another embodiment, the high torque motor interacts with the mandrels 11.

Alternatively, the rotation of the mandrels 11 may be in response to mechanical force. In one embodiment of the invention, the rotation of the mandrels of the feed unit 8A is controlled by a belt or chain connected to the blanket wheel 18. Thus, the rotation of the mandrels 11 and the metal containers 22 thereon can be synchronized with the rotation of the portable blankets 6A.

If necessary, the mandrels 11 move the metal containers 22 into contact with the blanket segment 6A at the transfer location 25. In one embodiment, the mandrel 11 of the supply unit 8A is positioned at least partially in the interior of the metal container 22 supported by the supply unit 8A. Thus, the mandrel can support a portion of the side wall of the metal container 22 while the metal container contacts the blanket segment 6A. The mandrel 11 may be configured to press the outer surface 24 of the metal container 22 against the blanket so that the decoration material is transferred to the metal container. In another embodiment, the mandrel 11 contacts a portion of the outer surface of the metal container 22. If desired, the mandrel can support the metal container 22 by contacting a portion of the closed end wall of the metal container 22.

After the decoration 7 is transferred to the metal container 22, the blanket segment 6 can be cleaned, if necessary, using the cleaning system 14. For example, in one embodiment of the present invention, the cleaning system 14 removes any residual ink or toner from the outer surface of the blanket segment 6 before new decoration material is applied by the digital printing unit 4 to form a new decoration 7 on the offset segment 6. canvases. In one embodiment, the cleaning system 14 contacts the outer surface of the blanket segment 6 during cleaning. In another embodiment, the cleaning system 14 cleans the blanket segment 6 non-contact.

Decorator 2 may further include a temperature control device 5A. The temperature control device 5A is designed to control the temperature of the 6A segments of the blanket. Specifically, the temperature control device 5A can heat or cool the blanket segments 6A to a predetermined temperature. In this way, the temperature control device 5A can change the characteristics of decoration materials such as printing ink applied to the blanket segments 6A. More specifically, the viscosity of the ink can be controlled by varying the temperature of the blanket segments 6A. The temperature of the segments 6A of the blanket can also change other characteristics of the ink applied by the digital printing units 4. For example, changing the temperature of the segments of a blanket can: affect the flow of ink on the segments of the blanket, change the thickness of the ink on the segments of the blanket, and change the appearance of the printing ink. In one embodiment, the temperature of the blanket segments can be adjusted to change the ink droplet size used to form the decoration 7. The temperature of the blanket segments 6A can also be adjusted by the temperature control device 5A for thermal pre-curing *, or at least partially fixing or curing decoration materials, including printing ink, applied to the segments of the blanket. For example, heating the segments of a blanket to a predetermined temperature can thermally cure or “pre-cure” the ink. In one embodiment, ink 43 transferred to a blanket segment from a digital printing unit 4 (such as an inkjet printhead 41) is at least partially thermally cured upon contact with a blanket segment 6A heated to a predetermined temperature. More specifically, the temperature control device 5A can control the temperature of the printing segment 6A so that the first printing ink 43 transferred to the printing segment by the first digital printing unit 4A is at least partially cured or cured before the second digital printing unit 4B transfers the second ink 43 to the blanket segment.

In one embodiment, the temperature control device 5A comprises at least one roller. This roller is aligned with the blanket wheel 18 so that each blanket segment 6A contacts the roller. The temperature control device 5A can heat or cool the segments of the blanket. In one embodiment, the temperature control device 5A is connected to a fluid source. The fluid source may include a heating element and a cooling element. If necessary, the fluid can be water. In another embodiment, the fluid is oil or gas. Additionally or alternatively, the temperature control device 5A may include an electrical heating element.

In one embodiment, the control system 12 is in communication with the temperature control device 5A. The control system can send a signal to the temperature control device 5A to adjust the temperature of the blanket segments 6A.

In one embodiment, the temperature control device 5A is positioned to contact the outer surface of the blanket segments 6A, as generally illustrated in FIG. 1. The temperature control device 5A may be located at any position around the circumference of the blanket wheel 18. In one embodiment, the temperature control device 5A is positioned between the image transfer position 25 and the first digital printing unit 4A. Other locations for the temperature control devices 5 are also provided. In one embodiment, the temperature control device 5 interacts with the blanket wheel 18. More specifically, the blanket wheel 18 may have a temperature control device 5 cooperating with each blanket segment 6A. For example, a temperature control device may be included in the blanket wheel 18 at each position in which the blanket segment will interact with the device. In one embodiment, the temperature control device 5A is configured to contactlessly control the temperature of the blanket segments 6A. For example, the temperature control device 5A may emit infrared light to control the temperature of the blanket segments.

The metal containers 22 may be transported to the supply unit 8 via a conveyor 10. In one embodiment of the present invention, the supply unit 8 receives metal containers 22 from an upstream equipment 26. The metal container 22 may be a beverage container, such as a can for beverage or beverage bottle, aerosol container, food tin, or container for any other type of product. Upstream equipment 26 may include a stretching and smoothing line or an impact extrusion line. An example of a well-known draw-and-iron metal container production line is generally illustrated and described in the document Inside a Ball Beverage Can Plant, available at http: //www.ball .com / Ball / media / Ball / Global / Downloads / How_a_Ball_Metal_Beverage_Can_Is_Made .pdf? ext = .pdf (last visited April 30, 2016), which is incorporated herein by reference in its entirety. Methods and apparatus for forming metal containers on an impact stamping production line are described in US Patent Application Publication No. 2013/0068352 and US Patent Application Publication No. 2014/0298641, each of which is incorporated herein by reference in its entirety.

Optionally, in another embodiment of the invention, the delivery unit 8 receives the end seals 34 from the end seals orientation system. Embodiments of orientation and decoration systems for end closures are described in US Pat. No. 9,259,913 and US Pat. No. 9,340,368, each of which is incorporated herein by reference in its entirety. The feed unit 8 then moves the end seals 34 into contact with the portable blankets 6 of the decorating device 2.

In one embodiment of the present invention, the upstream equipment 26 comprises a first printer or decorator. The first decorator may form the first decoration 23 on the outer surface area 24 of the metal containers 22. In one embodiment, the first decoration 23 comprises a base coat. In another embodiment, the first decoration 23 may comprise one or more text, numbers, and images.

In one embodiment, the first decoration 23 includes a window or empty area formed on the metal container 22. The decoration devices 2 of the present invention are configured to form a decoration 7 that is subsequently transferred to the metal container, whereby the decoration 7 is aligned with a first decoration 23 and a window. For example, the first decoration 23B may include an image such as a knitted fabric, an example of which is shown on container 28B. The decorator 2 can form the decoration 7 on the blanket 6, which is then transferred to the metal container 28B. The decoration may include, but is not limited to, decoration 30C containing the number "92" that is in a predetermined alignment with the first decoration 23B. A person skilled in the art will understand that the first decoration 23 and the decoration 30 formed by the decoration device 2 can be of any relative size and relative position to each other.

If necessary, the upstream equipment 26 may include a surface treatment unit 27. The surface treatment unit 27 may prepare a portion 24 of the outer surface of the metal container 22 to receive decoration 7 from the blanket 6. In one embodiment of the invention, the surface treatment unit 27 treats the outer surface portion 24 in one or more of the following ways: plasma treatment, anodizing treatment, application of the base coat material and application of the pre-coat. In one embodiment, the plasma treatment includes a corona treatment or air plasma treatment that uses low temperature corona plasma to alter the surface properties of the metal container 22. In another embodiment, one or more surface treatments from corona treatment, flame plasma treatment, chemical plasma treatment, electroplating, electrostatic coating, chemical coating, anodic oxidation, hot dipping and thermal spraying can be performed to pretreat the outer surface 24 of the metal container 22. The pretreatment usually improves adhesion and adhesion between decoration 7 applied decorating device 2, and the outer surface 24 of the metal container 22.

Decorated metal containers 28 can be transported from the feed unit 8, for example by a conveyor 13 to downstream equipment 32. Any suitable conveyor 13 can be used with the decorating device 2 of the present invention. The conveyor 13 can be the same or similar to the conveyor 10. In one embodiment, one or more conveyors 10, 13 comprise a belt or chain. In one embodiment, the conveyor 13 is an articulated chain. Suitable pivot chains are known to those skilled in the art and include those described in publication No. U.S. Patent Application 2017/0334659, which is incorporated herein by reference in its entirety.

Optionally, in one embodiment of the present invention, conveyor 13 transports decorated metal containers 28 to curing unit 17. The curing unit 17 may be the same or similar to the curing unit 16. Accordingly, the curing unit 17 functions to at least partially cure the decoration material forming the decoration 30 on the outer surface 24 of the container. The curing unit 17 may use at least one of heat energy and light of a predetermined wavelength to cure or fix the decoration material. In one embodiment, the curing unit 17 includes an ultraviolet or ultraviolet light-emitting diode (UV LED) lamp for curing. In another embodiment, the curing unit 17 is configured to cure or fix the decoration material using thermal energy. The curing block 17 may be used in conjunction with or instead of the curing block 16. More specifically, in one embodiment, the decorator includes only one of the curing block 16 and the curing block 17. The curing unit 17 can be used to cure one or more ink and toner materials on metal containers 28.

In one embodiment, downstream equipment 32 includes one or more of a coater, an oven, a wax applicator, a necking die *, a test device, a control station, and a stacker. on pallets. The coater can apply varnish (or other material such as oil varnish) to the inside of the metal container 28. The curing of the varnish is carried out in an oven. A thin layer of lubricant can be applied with a wax applicator to the portion of the container body closest to the open end of the metal container 28. The necking die device reduces the diameter of the portion of the metal body of the container and creates a curl for aerosol containers. The tester checks the container for unintentional holes or leaks. The inspection station can check the shape or other characteristics of the metal container 28. The palletizer can package the finished metal containers 28 for shipping or storage.

Examples of decorated metal containers 28A, 28B are also illustrated in FIGS. 1. Each of the metal containers 28A, 28B includes unique decorations 30A, 30B, 30C on the outer surface area 24. In addition, decorations 30 can be formed in a predetermined alignment with the first decoration 23 applied by upstream equipment 26. container 28. In addition, decorations 30 may include text, customer identification, brand information, instructions for use, or any other desired decoration or sign.

In addition, as described above, the decorator 2 may be used to decorate the end closure 34, the ROPP screw cap closure, and the crown cap 36. Examples of the end closure 34 and the crown cap 36 with decorative designs 30 formed by the decorating device 2 of the present invention are also illustrated in FIG. 1.

If necessary, two or more supply units 8 can cooperate with the decorating device 2A. More specifically, as shown in FIG. 1C, in one embodiment of the present invention, decorator 2A includes at least two feed units 8A, 8B. Decorator 2A includes a plurality of blanket segments 6A. The segments 6A of the blanket are sequentially located on the blanket wheel 18. The feed units 8A, 8B are aligned with the blanket wheel 18, whereby the feed unit 8A captures all other decorations 7 formed on the blanket segment 6A. More specifically, the supply unit 8A moves the metal containers 22 to a position of contact with each other segment 6A of the blanket at the first transfer position 25A. The second feed unit 8B moves the metal containers 22 into contact with the alternating blanket segments 6A at the second transfer position 25B. Thus, decorator 2A can run at a different speed compared to the container's production cycle. Additionally or alternatively, the blanket wheel 18 can rotate at a higher speed than the decorating device 2 with only one feed unit. Since the decorator 2A includes two supply units 8A, 8B, although the blanket wheel 18 rotates faster, the cycle speed of the supply units 8A, 8B may be the same or similar to the cycle speed of the decorating supply unit 8 illustrated in FIG. 1. Thus, the decorator 2A illustrated in FIG. 1C can decorate more containers per hour than the decorator of FIG. 1.

FIG. 3 generally illustrates a decorator 2B of another embodiment of the present invention. Decorator 2B includes digital printing units 4, one or more curing units 16 and a supply unit 8A, and optionally a curing unit 17, which are the same or similar to those used with decorator 2A. Decorator 2B also includes 6B continuous blanket. In particular, the blanket 6B is at least one endless loop of blanket material. The digital printing units 4 may include an inkjet print head 41 configured to transfer ink 43 to a blanket 6B, such as illustrated in FIG. 2A. If desired, at least one of the digital printing units 4 may be an electrophotographic system 40, as generally illustrated and described in conjunction with FIG. 2B. The relative positions and order of the digital printing units 4 can be changed.

The decorator 2B may include at least one temperature control device 5A configured to heat or cool the blanket 6B. The temperature control device 5A can be positioned to contact the outer surface of the blanket 6B. Additionally or alternatively, the decorator 2B may include a temperature control device 5A positioned to contact the inner surface of the blanket 6B. In another embodiment, the temperature control device 5A is configured to change the temperature of the blanket 6B without contacting the blanket.

In one embodiment, the blanket 6B has a width 65 (illustrated in FIG. 5) that is no less than the height of the metal container 22 to be decorated. If necessary, the width 65 of the blanket can be greater than the height of the container. In one embodiment, the blanket 6B is formed from the same or similar materials as the blanket segments 6A. The 6B blanket can be of any desired length. In one embodiment, the blanket 6B has a length ranging from about 5 m to about 20 m. In another embodiment, the length of the blanket 6B is up to about 50 m.

The 6B blanket can be tensioned to prevent unintentional or unwanted movement. More specifically, in one embodiment, decorator 2B is configured to maintain blanket 6B in a tension sufficient to resist forces received from metal containers 22 that contact blanket 6B to provide decoration 7.

In one embodiment, decorator 2B includes one or more tensioning mechanisms 54-62. The tensioning mechanisms can selectively contact the 6B blanket. Thus, in one embodiment, the tensioning mechanisms 54-62 may vary the tension of the blanket 6B. In one embodiment, decorator tensioning mechanisms 2B include at least one of the following: an inner tensioning roller 54, a rear side tensioning roller 56, a tensioner guide 58, a rotary tensioner 60, and a pinch roller 62. In one decorator embodiment, the guide surface the tensioner 58, configured to contact the blanket 6B, has a shape that is typically arcuate. The tensioning guide 58 can be of any size. Other arrangements and positions of tensioners 54-62 are also contemplated.

In one embodiment of the present invention, the decorator 2B includes one pinch roller 62 in the vicinity of the transfer position 25. If necessary, the rear side idler roller 56 is located after one or more servos 64 and the transfer station 25. The inner take-up roller 54 can be positioned just in front of the servo 64. The second inner take-up roller 54 can be positioned after the transfer position 25. If required, the tensioner 60A with a pair of rollers can be positioned past the transfer position 25. The tensioning guide 58 can also be positioned after the transfer station 25 and before the first digital printing unit 4.

If necessary, one or more tensioning mechanisms (such as the inner tensioner 54, the rear side tensioner 56, the tensioner guide 58, the rotating tensioner 60, and the pinch roller 62) may be connected to the actuators. More specifically, the tensioning mechanisms 54-62 can be positioned in a controlled manner with respect to the blanket 6B. Thus, one or more of the tensioning mechanisms 54-62 can be moved relative to the blanket 6B. In another embodiment, control system 12 may send signals to one or more actuators interacting with tensioners 54-62. These signals can cause the actuators to move the respective tensioner 54-62 in a specific direction or manner. For example, as shown in FIG. 3A, a signal from the control system 12 may cause an actuator associated with the inner idler roller 54 to press against the inner surface of the blanket 6B. Thus, the inner take-up roller 54 can change the tension of the blanket 6B. In the same way as shown in FIG. 3B, the control system 12 may send a signal to the rear side idler roller 56 actuator to move it inwardly relative to the blanket 6B to change the blanket tension. If necessary, the actuator can also interact with the servo 64. Accordingly, the control system 12 can send a signal to the actuator to move the servo 64 to increase or decrease the tension of the blanket 6B. By changing the position of the servo 64 with the actuator, it is possible to advantageously adjust the tension of the transfer web without adding a point of deflection with respect to the blanket.

As shown in FIG. 3C, the tensioning guide 58 is illustrated in the on position in contact with the outer surface of the blanket 6B. More specifically, the tensioner guide 58 is generally shown in an actuated position. Thus, the tensioning guide 58 can move relative to the blanket 6B in response to a signal received from the control system 12. FIG. 3C also illustrates a tensioning guide 58 with a surface having a shape that generally becomes arcuate when in contact with the blanket. The tensioner guide can be of any desired size. In addition, the radius of curvature of the arcuate surface can be of any given size.

By selectively positioning tensioners 54-62 and optionally a servo drive 64 around the inner and outer surfaces of the blanket 6B, the tension of the blanket 6B can be adjusted to be substantially constant. In addition, the location of the tensioners 54-62 and / or the servo drive 64 can be selected to prevent or reduce vibration of the blanket 6B. In addition, the combination of tensioning mechanisms 54-62 or servo drive 64 can eliminate or reduce warpage or other unintentional movement of the blanket. Accordingly, adjusting the tension of the blanket 6B using the tensioning mechanisms 54-62 and / or the servo drive 64 can improve the quality of the decorations 30 formed on the metal containers 28 and increase the life of the blanket.

In one embodiment, one or more of the tensioning mechanisms 54, 56, 60, 62 may be actuated as needed to rotate the blanket 6B. In another embodiment, the tensioning mechanisms 54, 56, 60, 62 are free to rotate.

In one embodiment, the rotary tensioner 60 includes two or more rollers 61 as a rotary tensioner 60A with a pair of rollers shown in FIG. 3D. More specifically, the rotary take-up mechanism 60A of one embodiment of the present invention may include a first roller 61A configured to contact a first side of the blanket 6B. The second roller 61B may be configured to contact the second side of the blanket 6B. The rollers 61A, 61B are interconnected by a transmission mechanism 63. If necessary, the rollers 61A, 61B can have the same or different diameters. In one embodiment, rotary tensioner 60A may be used with decorator 2B in addition to or instead of rotary tensioner 60.

Optionally, decorator 2B includes a pinch roller 62. In one embodiment, pinch roller 62 applies force to the blanket 6B while transferring decoration 7 to the metal container 22. In another embodiment, the pinch roller 62 applies force to the blanket surface 6B, which is substantially opposed to the outer surface of the blanket in contact with the metal container 22 during the transfer of the decoration to the metal container.

In one embodiment, the pinch roller 62 applies a force to the blanket 6B that is substantially equal to the force applied to the blanket by the metal container 22 when the decoration 7 is transferred to the metal container. Thus, the pinch roller 62 eliminates or minimizes the dynamic impact on the blanket 6B. The balancing forces applied to the blanket by the pinch roller 62 and the metal container 22 can also minimize the wear of the blanket. Accordingly, the decorator 2 can operate for a longer period of time without maintenance compared to a similar decorator that does not balance the force received from the metal container.

In one embodiment, decorator 2 may include a plurality of pinch rollers 62A, 62B, 62C. The pinch rollers 62 may be oriented so as to vary the tension of the blanket 6B in the vicinity of the feed unit 8. For example, decorator 2B may include two or more pinch rollers 62 such that the tension of the blanket 6B at the transfer position 25 in the vicinity of the feed unit 8A is different from the tension of the other portions of the blanket 6B. Isolating the tension of the blanket in the vicinity of the contact between the blanket and the metal container can minimize or eliminate inadvertent and unwanted movement of the blanket 6B during the contact of the blanket 6B with the metal container 22 during the transfer of decoration material. Accordingly, the force received from the metal container 22 does not inadvertently move the blanket 6B when the digital printing units 4 move the decoration material towards the blanket 6B. This improves the quality of the finish.

In one embodiment, decorator 2B includes a first pinch roller 62A located upstream of the transfer position 25 in which decorating material 7 is transferred from the blanket 6B to a metal container 22. Optionally, the second pinch roller 62B may be positioned substantially at the transfer position 25. In one embodiment, the third pinch roller 62C is located downstream of the transfer position 25.

In one embodiment, the decorator 2B includes at least one servo drive 64 operable to rotate the blanket 6B at a predetermined speed. The servo drive 64 is configured to apply a force to the blanket 6B, as a result of which the blanket 6B rotates at a predetermined speed. In one embodiment of the present invention, the servo 64 is configured to pull the blanket 6B. Additionally or alternatively, the servo drive 64 may be configured to push the blanket 6B. If necessary, the first servo drive 64 can be configured to push the blanket 6B and the second servo 64 can be configured to pull the blanket 6B.

The servo drive 64 can rotate the blanket 6B substantially continuously. If necessary, the servo drive 64 can change the rotation speed of the 6B blanket. For example, in one embodiment of the present invention, the servo 64 reduces the rotational speed. The decrease in the rotational speed may be associated with one or more operations of the decorator 2B. More specifically, in one embodiment, the servo 64 reduces the rotational speed during the curing of the decoration 7 with one or more curing units 16. In another embodiment, the rotational speed of the blanket 6B is increased by the servo drive 64 during other operations of the decorating device 2B. Accordingly, in another embodiment, the servo drive 64 increases the rotational speed during one or more transfers of the decoration material to the blanket 6B using the digital printing unit 4 and transfer the decoration 7 to the metal container 22.

In another embodiment, the servo drive 64 periodically rotates the blanket 6B. More specifically, the servo drive 64 can periodically start and stop the rotation of the blanket 6B. Thus, the blanket 6B can be intermittently stopped during the formation of the decorations 7 with the digital printing units 4, during the curing of the decoration material with the curing units 16, and / or during the transfer of the decorations 7 to the metal container 22. Thus, the blanket 6B can be in a fixed orientation with respect to the metal container 22 when the decoration 7 is transferred to the metal container 22.

In one embodiment, the servo 64 is a load balancing servo. The load balancing servo 64 can adjust the force applied to the blanket 6B to maintain a substantially constant rotational speed of the blanket 6B. More specifically, the load balancing servo 64 may apply more or less force to maintain a substantially constant blanket rotation speed. In one embodiment, the load balancing servo 64 is configured to adjust the force applied to the blanket 6B such that the tension on the blanket 6B is substantially constant. Thus, the load balancing servo 64 can maintain a constant tension on the blanket 6B in one or more positions. In one embodiment, the load balancing servo 64 may adjust the force applied to the blanket 6B such that the tension is substantially constant at one or more transfer positions 25 and print areas adjacent to one or more units 4A-4D digital printing. By keeping the web tension substantially constant, the load balancing servo 64 reduces "noise" or vibration in the 6B blanket. This improves the quality of decorations generated by the digital printing units 4, and also reduces distortion or other errors that occur when the decorations are transferred to the metal container 22 at the transfer position 25.

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

In one embodiment, the supply unit 8A is configured to rotate the metal container 22 such that the outer surface 24 moves at a speed substantially equal to the rotational speed of the blanket 6B. In one embodiment, the surface speed of the rotating container 22 is substantially equal to the rotational speed of the pinch roller 62. Thus, the dynamic effect on the blanket 6B is minimized. If necessary, the supply unit 8A may include mandrels 11 for supporting the metal containers 22, similar to the supply unit 8A described in conjunction with FIG. 1. The mandrels 11 can rotate the metal containers 22 in contact with the blanket 6B at the transfer position 25. In one embodiment, the mandrels 11 rotate at a speed substantially equal to the rotational speed of the blanket 6B. In another embodiment, the control system 12 may send signals to the mandrels 11 to control the rotation of the mandrels. In one embodiment, a servo or other electrical or mechanical means is configured to rotate the mandrels 11. Optionally, the mandrels 11 are the same or similar to the decorator mandrels 2A. Accordingly, the mandrels 11 can rotate in response to the force received from the belt or chain connected to the drive unit 64.

The supply unit 8A may be located at a different location relative to the blanket 6B. For example, in one embodiment of the invention, the supply unit 8A is positioned such that the metal containers 22 can move towards the supply unit 8A by gravity. Accordingly, in one embodiment, the supply unit 8A is positioned adjacent to one of the rotary tensioner 60 and the servo drive 64. Optionally, in another embodiment, the supply unit 8A is positioned adjacent to the curing unit 16D.

In one embodiment of the present invention, the blanket 6B can rotate at a speed of about 150 to about 250 meters per minute. When the 6B blanket rotates at about 200 meters per minute, the 2B decorator can decorate from about 700 to about 900 metal containers per minute. In another embodiment, at a rotation speed of about 200 meters per minute, the decorator decorates about 725 to 775 metal containers per minute.

As shown in FIG. 3E, the decorator 2B may optionally include two feed units 8. The feed units 8 can be positioned with respect to the blanket 6B so that there are two transfer positions 25A, 25B. More specifically, the first supply unit 8A can be positioned upstream of the second supply unit 8B with respect to the blanket 6B. Thus, the first and second supply units 8 can sequentially decorate the metal containers 22 using one or more production lines. In addition, individual conveyors 13A, 13B can interact with each of the feeding devices 8A, 8B. Thus, metal containers from two separate production lines can, if necessary, be decorated with a decorating device 2B and subsequently separated by conveyors 13A, 13B for further processing without mixing the metal containers together. In one embodiment, the first feed unit 8A moves the metal containers 22 into contact with every second decoration 7 on the blanket 6B. For example, decoration 7A is transferred to a metal container 22 located on the mandrel 11 of the supply unit 8A. However, the decorations 7B, 7D pass by the supply unit 8A and are transferred to the metal containers 22, which are moved in contact with the blanket 6B by the second supply unit 8B. As shown in FIG. 3E, blank space on blanket 6B separates decoration 7B from decoration 7D. The empty space is the position of the blanket 6B, which previously contained decoration, transferred to a metal container supported by the first supply unit 8A. If necessary, the supply unit 8A can rotate in the first direction and the supply unit 8B can rotate in the second opposite direction.

FIG. 4, another embodiment of the decorating device 2C of the present invention is illustrated. Decorator 2C is similar to decorator 2B and includes a single blanket 6C that is continuous as well as a digital printing unit 4 and a feeding unit 8. The 6C blanket may be the same or similar to the decorating blanket 6B. 2B. It is noteworthy that the 6C blanket has a different path of movement compared to the 6B blanket. More specifically, the blanket 6C follows an asymmetrical path around a plurality of tensioners 54-62 and servo drives 64 with respect to the digital printing units 4 and curing units 16.

In one embodiment, the supply unit 8C includes a plurality of mandrels 11 for positioning metal containers 22 in contact with the blanket 6. The mandrels 11 can rotate in one or more directions as needed. In one embodiment, the servo is in communication with the mandrels 11. In one embodiment, the servo is in communication with each mandrel. The servo drive can selectively rotate the mandrel interacting with it. In another embodiment, the servo is controlled by a signal from the control system 12. More specifically, the control system 12 may send a signal to the servo to rotate the mandrel 11 in a specific direction at a specific speed. Optionally, in another embodiment, the mechanical or electrical means is adapted to rotate the mandrels 11. In another embodiment, a high torque motor interacts with the mandrels 11. Examples of mandrels that can be used with the feed units 8 of the present invention are described in US Pat. No. 8,596,624 and US Pat. No. 8,708,271, each of which is hereby incorporated by reference in its entirety.

In one embodiment, decorator 2C includes one or more tensioners 54-62 similar to decorator 2B. The tensioning devices can be located in different positions in relation to the 6C blanket. In one embodiment, decorator 2C includes at least one of an inner idler roller 54, a rear idler roller 56, a idler idler 58, a rotary idler 60, and a pinch roller 62. Optionally, the order, location, and number of idlers mechanisms 54 - 62 can be changed. For example, in one embodiment, decorator 2C may include one pinch roller 62. In another embodiment, decorator 2C includes three pinch rollers 62. Optionally, the first pinch roller 62A may be located upstream of the decoration transfer position 25. ... In another embodiment, the pinch roller 62B is positioned in the vicinity of the transfer position 25. In addition, the additional roller 62C can be positioned downstream of the transfer position 25.

Tensioners 54, 56, 60 and 62 are free to rotate. Additionally or alternatively, at least one of the tensioners 54, 56, 60, and 62 may interact with a servo to provide a rotational force applied to the blanket 6C. In one embodiment, one or more tensioners 54-62 and a servo drive 64 are displaceable relative to the blanket 6C. Accordingly, the tensioners 54-62 and / or the servo drive 64 can come into contact and out of contact with the blanket 6C. In one embodiment, the control system 12 may send a signal to an actuator in communication with the tensioner 54-62 or the servo 64 to change the position of the tensioner or servo. Thus, the control system 12 can adjust the tension of the blanket 6C.

Decorator 2C may also include at least one servo 64. The servo 64 may be the same or similar to the servo 64 of decorator 2B. Accordingly, the servo 64 can rotate substantially continuously. In another embodiment of the invention, the servo drive 64 rotates intermittently, causing the blanket 6C to alternate between periods of travel and periods of rest. In one embodiment, the servo 64 is controlled by the control system 12. More specifically, the control system 12 may send signals to the servo 64 to change the rotation speed of the servo to start the rotation of the servo and stop the servo.

Optionally, the decorator 2C may include at least one temperature control device 5A configured to heat or cool the blanket 6C to a predetermined temperature. The temperature control device 5A can be positioned to contact the outer surface or the inner surface of the blanket 6C. Alternatively, the temperature control device 5A is configured to change the temperature of the blanket 6C without contact.

As shown in FIG. 5, in one embodiment, the blanket 6 may comprise at least two segments 66. More specifically, in one embodiment, the blanket 6C comprises a plurality of segments 66A-66D. In one embodiment, each segment 66 is generally parallel to one or more adjacent segments. If desired, each segment 66 can be substantially the same size and shape. In another embodiment, the segments 66 are made of the same materials. In another embodiment, at least one segment 66A is comprised of a different material from segments 66B-66D.

If desired, segment 66B may be connected to at least one adjacent segment 66A, 66C along longitudinal edge 67. In another embodiment, segments 66 are connected together along longitudinal edges 67 at least in the vicinity of transfer position 25 when decorating material transferred to metal container 22.

The blanket 6C has a width of 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 height of the container.

In one embodiment, the segments 66 are not interconnected. Accordingly, in one embodiment, the tension of the segments 66 can be individually adjusted. For example, in one embodiment, one or more tensioners 54-62 can selectively adjust the tension of one or more segments 66.

In another embodiment of the invention, at least one servo drive 64 interacts with each segment 66. Thus, the rotational speed of each segment 66 can be selectively controlled with respect to other segments. In addition, one segment 66A may stop while other segments 66B through 66D continue to rotate. While FIG. 5 illustrates only four segments 66A-66D, one skilled in the art will appreciate that blanket 6C may include any number of segments 66. If desired, blanket 6C can be formed from two to eight segments 66.

In another embodiment, at least one segment 66A may follow a different path through decorator 2C as compared to one or more segments 66B-66D. Thus, at least one segment 66 can pass one or more digital printing units 4. If desired, at least one segment 66 may have a different length from the other segment 66. Alternatively, at least one segment 66 may receive decoration material from the digital printing unit 4, which does not transfer the decoration material to one or several other segments 66.

The 66 segments of the 6C blanket provide many benefits. In one embodiment, more metal containers 22 may be decorated with blanket 6 including segments 66. More specifically, the speed of rotation of blanket 6C is generally limited by the speed at which digital printing units 4 can transfer the decoration material onto the blanket. The parallel blanket segments 66 increase the productivity of the same main metal container handling unit, such as the feeding unit 8. In addition, the segments 66 of the blanket provide redundancy. This guarantees a stable exit of the decorated metal containers from the decorating device. More specifically, in one embodiment, each segment 66 may operate independently. Accordingly, if one segment 66 stops, the other segments can continue to rotate relative to the digital printing units. In addition, the individual blanket segments 66 can isolate the blankets from noise generated when the image is transferred to metal containers. For example, if each blanket segment 66 interacts with a separate feed unit 8, for example, as described in conjunction with FIG. 5A, vibration and noise in the blanket 6C generated during image transfer will be reduced. The noise in the blanket 6C can be further reduced by transferring the decoration from the first segment 66A to the metal container at a different time compared to the transfer time of the decoration on the second segment 66B, which is transferred to another metal container. The individual blanket segments 66 can also allow different operating temperatures of the segments to be obtained. This can further reduce wear and damage to the 6C blanket.

In another embodiment of the invention, the decorating device 2 supply unit 8 may interact with each segment 66 of the blanket 6. More specifically, and now with reference to FIG. 5A, a partial cross-sectional view of a decorator 2D generally illustrates another embodiment of the present invention. Decorator 2D is similar to decorators 2B, 2C, and generally includes digital printing units 4, cleaning system 14, curing units 16, 17, tensioner 54-60, and servo 64, which are not shown for clarity. Notably, the 2D decorator includes a continuous blanket 6D comprising two segments 66A, 66B that are aligned with the two feed units 8 at the transfer positions 25A, 25B. The pinch roller 62 is positioned to support the 6D blanket during contact with the metal containers. If necessary, two separate pinch rollers 62A, 62B are provided so that one pinch roller 62A, 62B can interact with each blanket segment 66. Thus, the digital printing units 4 can transfer the decoration material such as ink or toner to the image forming blanket 6D 7. The first segment 66A of the blanket 6D can then transfer the image 7A to the first metal container 22A. The second segment 66B can similarly transfer the second image 7B to the second metal container 22B. Segments 66A, 66B can rotate through the 2D decorator at the same speed or at different speeds as needed. In one embodiment, a 2D decorator can decorate about 1400 to 1600 containers per minute when the 6D blanket rotates at about 200 meters per minute.

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

FIG. 5A also illustrates a mandrel 11A of one embodiment of the present invention. If necessary, the mandrel 11A can be moved relative to the blanket 6D. More specifically, in one embodiment, the mandrel 11A is movably connected to the feed unit 8. If necessary, an actuator can interact with the mandrel 11A. Thus, the mandrel can selectively move the metal container 22 disposed thereon into and out of contact with the blanket.

Although the blanket 6D is illustrated with two segments 66 aligned with two supply units 8, any number of segments 66 and supply units 8 can be used with the decorating device 2 of the present invention. More specifically, in another embodiment, the blanket 6C illustrated in FIG. 5 can cooperate with four feed units 8. In one embodiment, decorator 2, including four feed units 8 interacting with four segments 66 of blanket 6, can decorate containers in an amount between about 1,850 and about 2,100 containers per minute when the blanket 6 rotates at a speed of about 200 meters. per minute.

FIG. 6 generally illustrates a control system 12 for one embodiment of the present invention. The control system 12 is generally illustrated with hardware elements that can be electrically coupled through a bus 68. The hardware elements can include one or more central processing units (CPUs) 70; one or more input devices 72 (eg, mouse, keyboard, etc.); and one or more output devices 74 (eg, display device, printer, etc.). Management system 12 may also include one or more memory 76. In one embodiment, memory 76 may be disk drives, optical storage devices, solid state storage devices such as random access memory ("RAM"), and / or read-only memory. storage device ("ROM"), which can be programmable, flash-upgradeable, and / or the like.

The control system 12 may further include one or more of computer readable media readers 78; communication system 80 (eg, modem, network card (wireless or wired); infrared communication device, etc.); and a work memory 82, which may include random access memory devices (RAM) and read-only memory (ROM), as described above. In some embodiments, control system 12 may also include an accelerator 84, which may include a digital signal processor (DSP), a special purpose processor, and / or the like. If necessary, the control system 12 also includes a database 86. The database may include information related to decorations 23 applied to metal containers 22 using upstream equipment 26. Additionally or alternatively, the database 86 may include information describing decorations 7 to be generated by the decorating device 2 of the present invention.

The computer-readable media reader 78 may be further connected to the computer-readable media together (and, if necessary, in combination with the storage devices 76) collectively representing remote, local, fixed and / or removable storage devices, plus temporary and / or storage media. more permanent storage of machine-readable information. Communication system 80 may permit communication with computer network 88 and / or any other data processing. If desired, the control system 12 can access data stored on a remote storage device, such as a database 90, by connecting to a computer network 88. In one embodiment, the network 88 can be the Internet.

Control system 12 may also include program elements shown as currently located in work memory 82. Program elements may include an operating system 92 and / or other code 94, such as program code that implements one or more methods and aspects of the present invention. ... In one embodiment of the invention, instructions for sending signals to the digital printing unit 4 for generating decoration 7 are stored in the work memory 82. In another embodiment, the work memory 82 includes instructions regarding signals to be sent to the exposure element 46 for forming decoration 7 on conductor 42. If necessary, work memory 82 may include instructions relating to aspects of one or more decorating devices 2, digital printing unit 4, feeding unit 8, mandrels 11, cleaning system 14, unit 16, 17 curing, blanket wheels 18, upstream equipment 26, surface treatment unit 27, downstream equipment 32, electrophotographic system 40, an actuator interacting with tensioners 54-62 of decorating devices 2B, 2C, servo drive 64 and pressure roller 62. Respectively naturally, in one embodiment, the control system 12 can send signals to one or more digital printing units 4, feed unit 8, mandrels 11, curing units 16, 17 and blanket wheel 18, as well as a servo drive 64 to synchronize the operation of decorating device 2 Thus, the control system 12 can send signals to the digital printing unit 4 to form decorations 7 on the blanket 6, whereby the decorations 7 are aligned with the metal containers 22 on the supply unit 8.

One skilled in the art will appreciate that alternative embodiments of the control system 12 may have numerous variations from that described above. For example, custom hardware can also be used, and / or specific items can be implemented in hardware, software (including portable software such as a mini application), or both. In addition, a connection with other computing devices such as network I / O devices can be used.

The control system 12 can be in communication with one or more components from among decorating devices 2, digital printing units 4, feeding unit 8, input conveyors 10, output conveyors 13, cleaning system 14, additional curing units 16, 17, blanket wheels 18 , tensioners 54-62 and a servo drive 64. The control system 12 can send signals to the digital printing units 4 to adjust the position of the decoration 7 formed on the blanket 6. The control system 12, in one embodiment of the invention, is also configured to provide unique signals to each of the digital printing units 4 to form unique decorations 7 on each of the blankets 6. Accordingly, the control system 12 can send a unique design for each decoration 7 to the digital printing units 4.

Suitable control systems 12 are 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 an MS Windows operating system. If desired, the control system 12 can be a tablet computer, laptop computer, and similar computing devices. In one embodiment, control system 12 is a data processing system that includes, but is not limited to, one or more of: at least one input device (eg, keyboard, mouse, or touch screen); output devices (for example, display); video card; a communication device (such as an Ethernet card or wireless device); permanent storage device (eg hard disk); temporary storage device (eg random access memory); and processor. The control system 12 can be any programmable logic controller (PLC). One example of a suitable PLC is the Controllogix PLC manufactured by Rockwell Automation, Inc., although other PLCs may also be considered for use 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 to limit the invention to the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments described and shown in the drawings have been selected and described in order to best explain the principles of the invention, practical application, and enable those skilled in the art to understand the invention.

While various embodiments of the present invention have been described in detail, it will be appreciated that modifications and changes to these embodiments will be apparent to those skilled in the art. In addition, references made herein to "the present invention" or aspects thereof are to be understood to mean certain embodiments of the present invention, and are not necessarily to be construed as limiting all embodiments to the specific description. It should be clearly understood that such modifications and variations are within the scope and spirit of the present invention, as set forth in the following claims.

Claims (63)

1. A device for applying decorative design to the outer surface of a metal container, containing: the first segment of the blanket; the second segment of the blanket; digital printing unit with a given alignment with respect to the first and second blanket segments, while the digital printing unit is configured to transfer the decorating material to the first and second blanket segments to form the first decorative design on the first blanket segment and the second decorative design on the second segment of the blanket; a first feed unit for moving the first metal container in contact with the first blanket segment for transferring the first decoration from the first blanket segment to the outer surface of the first metal container, wherein the first blanket segment can be separated by a first distance from the second blanket segment in the vicinity of the digital printing unit and the first blanket segment may be separated by a second distance from the second blanket segment in the vicinity of the first feed unit; and a second feed unit for moving the second metal container in contact with the second blanket segment downstream of the first feed unit for transferring the second decoration from the second blanket segment to an outer surface portion of the second metal container. 2. The apparatus of claim 1, wherein the decorating material includes an ink and / or toner material. 3. The apparatus of claim. 1, in which the first and second segments of the blanket are part of a continuous loop of material or the first and second segments of the blanket are separate segments of the blanket. 4. The device of claim 1, wherein the first distance is less than the second distance. 5. The apparatus of claim. 1, wherein the first and second blanket segments are movable at a first speed in the vicinity of the digital printing unit and the first and second transfer canvas segments are movable at a second speed in the vicinity of the feed unit. 6. The apparatus of claim 5, wherein the first speed is less than the second speed. 7. The apparatus of claim 1, further comprising a curing unit located downstream of the digital printing unit and upstream of the first and second supply units, wherein the curing unit is configured to at least partially cure the decorating material, transferred to the first and second segments of the blanket. 8. The apparatus of claim 1, further comprising a temperature control device configured to control the temperature of the first blanket segment. 9. The apparatus of claim 1, wherein the digital printing unit is an electrophotographic system comprising a conductor, a charging element, an exposure element, and a developing unit that supplies decoration material. 10. The apparatus of claim 1, wherein the digital printing unit is an inkjet printhead and the decoration material is ink. 11. The apparatus of claim 10, further comprising one or more of the following systems: a thermal system and an ultraviolet system configured to adjust the viscosity of the ink. 12. A method of forming a decorative design on sections of the outer surface of cylindrical containers, characterized in that: transfer the decorating material from the digital printing unit to the first segment of the decorator's blanket in such a way that the decorating material forms a decorative design on the first segment of the blanket, the decorating material comprising printing ink and / or toner material, wherein the first segment of the blanket is configured to be located at the first distance from the second segment of the blanket in the vicinity of the digital printing unit; the first cylindrical container is fed; positioning the first cylindrical container in the feed unit of the specified decorator; change the distance between the first blanket segment and the second blanket segment as the first and second blanket segments move from the digital printing unit to the first feed unit, while the first blanket segment is configured to be at a second distance from the second blanket segment in the vicinity of the first feed unit; moving a portion of the outer surface of the first cylindrical container in contact with the first segment of the blanket, while the first decoration is transferred from the first segment of the blanket to the portion of the outer surface of the first cylindrical container; transferring more decoration material from the digital printing unit to the second blanket segment to form a second decorative design on the second blanket segment; a second cylindrical container is fed; positioning the second cylindrical container in the second supply unit of the specified decorator; and moving a section of the outer surface of the second cylindrical container in contact with the second segment of the blanket in a position located downstream of the first supply unit, while the second decoration is transferred from the second segment of the blanket to the section of the outer surface of the second cylindrical container. 13. The method of claim 12, wherein the first and second blankets are separate blanket segments and / or part of a continuous material loop. 14. The method of claim 12, wherein the second distance is greater than the first distance. 15. The method of claim 12, wherein the first blanket segment is closest to the second blanket segment. 16. The method of claim 12, wherein ink is injected from the inkjet printhead onto the first segment of the blanket when the decorating material is transferred from the digital printing unit. 17. The method according to claim 12, wherein when transferring the decorating material from the digital printing unit: charging the conductor of the digital printing unit, the digital printing unit being an electrophotographic system; irradiating selected portions of the conductor with light to form a hidden decoration; transferring the decoration material to the hidden decoration, the decoration material being a toner material; and transfer the decorating material from the conductor to the first segment of the blanket. 18. The method according to claim 12, in which the decoration on the first segment of the blanket is at least partially cured using a curing unit, wherein the curing unit is positioned downstream of the digital printing unit, but upstream of the unit filing. 19. The method of claim 12, wherein the first segment of the blanket is heated to a predetermined temperature and / or the viscosity of the decorating material supplied to the digital printing unit is adjusted. 20. The method of claim 12, wherein the first and second blanket segments are movable at a first speed in the vicinity of the digital printing unit, and the first and second blanket segments are movable at a second speed in the vicinity of the feed unit. 21. The method of claim 20, wherein the first segment of the blanket is accelerated to a second speed, the second speed being greater than the first speed. 22. A device for applying decorative design to the outer surface of a metal container, comprising: the first segment of the blanket; digital printing unit with a predetermined alignment with respect to the first segment of the blanket, while the digital printing unit is an electrophotographic system capable of transferring the decorating material to the first segment of the blanket by means of charging the conductor of the electrophotographic system; irradiating selected sections of the conductor with light to form a hidden decoration; transferring a decoration material to a hidden decoration on a conductor, the decoration material being a toner material; and transferring the decorating material from the conductor to the first segment of the blanket to form the decorative design on the first segment of the blanket; and a feed unit for moving the metal container in contact with the first blanket segment for transferring decoration from the first blanket segment to the outer surface of the metal container, wherein the first blanket segment can be separated by a first distance from the second blanket segment in the vicinity of the digital printing unit, and the first blanket segment may be separated by a second distance from the second blanket segment in the vicinity of the feed unit. 23. The apparatus of claim 22, further comprising a second feed unit for moving the second cylindrical container in contact with the second blanket segment to transfer the second decoration from the second blanket segment to the outer surface of the second cylindrical container. 24. A method of forming a decorative design on a section of the outer surface of a cylindrical container, characterized in that: transfer the decorating material from the digital printing unit, which is an electrophotographic system, to the first segment of the decorator's blanket, while charge the conductor of the digital printing unit; irradiating selected portions of the conductor with light to form a hidden decoration on the conductor; transferring the decoration material to a hidden decoration on the conductor, the decoration material being a toner material; and transferring the decorating material from the conductor to the first segment of the blanket so that the decorating material forms a decoration on the first segment of the blanket, the first segment of the blanket being configured to be at a first distance from the second segment of the blanket in the vicinity of the digital printing unit; a cylindrical container is fed; positioning the cylindrical container in the feed unit of the specified decorator; change the distance between the first blanket segment and the second blanket segment as the first and second blanket segments move from the digital printing unit to the feeding unit, while the first blanket segment is configured to be at a second distance from the second blanket segment in the vicinity of the block filing; and the section of the outer surface of the cylindrical container is moved in contact with the first segment of the blanket, while the decorative design is transferred from the first segment of the blanket to the section of the outer surface of the cylindrical container. 25. The method according to claim 24, wherein transferring more decoration material from the digital printing unit to the second blanket segment to form a second decorative design on the second blanket segment; a second cylindrical container is fed; positioning the second cylindrical container in the second supply unit of the specified decorator; and moving a section of the outer surface of the second cylindrical container in contact with the second segment of the blanket in a position located downstream of the feed unit, while the second decoration is transferred to the section of the outer surface of the second cylindrical container.

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