Armored Cable Indicia Printing on Crown-and-Valley Sheaths
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Solution Overview
Problem
The irregular exterior surface of armored electrical cables poses a challenge for effectively marking necessary information such as wire size, voltage rating, and other specifications, making it difficult to apply indicia consistently and legibly.
Innovation Solution
A method involving the use of ink jet print heads positioned at specific angles relative to the cable's longitudinal axis, applying ink to the sheath with defined crowns and valleys, using contrasting colors and stripes to ensure clear and readable indicia, and a continuous printing process during cable manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional marking methods are used on armored cable, then the process is simple, but the irregular exterior surface makes it difficult to apply indicia consistently and legibly
Solution Approach 1:
The printing system is designed to accommodate the dynamic, irregular surface of armored cable with crowns and valleys. The ink jet print heads are positioned and angled (60-120 degrees to longitudinal axis) to dynamically adapt to the varying surface geometry, ensuring consistent indicia application despite the cable's irregular exterior profile
Solution Approach 2:
The patent introduces angular positioning as an additional dimension for the print heads. By positioning outlets at specific angles (60-120 degrees) relative to the cable's longitudinal axis, the system compensates for surface irregularities in three-dimensional space, enabling legible marking on the complex armored cable surface
2Manufacturing precision
If ink jet printing is used on armored cable with crowns and valleys, then legible indicia can be achieved, but the printing process becomes more complex
Solution Approach 1:
The system optimizes specific parameters including the angle of the print head outlets (60-120 degrees to longitudinal axis) and the spacing from crowns (0.125-1 inch) to achieve legible indicia. These parameter adjustments compensate for the difficult-to-manufacture armored cable surface, making the printing process effective despite the complex substrate
3Manufacturing precision
If print heads are positioned at specific angles and distances, then consistent marking is achieved, but the system setup becomes more complex
Solution Approach 1:
The patent applies local quality by positioning print heads with specific outlet angles (60-120 degrees) and distances (0.125-1 inch from crowns) tailored to the local geometry of the armored cable surface. This localized positioning strategy ensures consistent indicia placement on the varying crown and valley structures without requiring complex adjustment mechanisms
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables consistent and legible marking of cable characteristics along the cable's length, enhancing readability and durability of the applied indicia.
Implementation Method 1
An outlet of at least one ink jet print head may be positioned adjacent the sheath at an angle of 60 degrees to 120 degrees with respect to a longitudinal axis of the sheath. The at least one ink jet print head may be used to print marking indicia on the sheath
Data Source
AI summary
A method according to the teachings of the present disclosure may include disposing a sheath around a conductor assembly, with an outer surface of the sheath defining spaced apart crowns and valleys. An outlet of at least one ink jet print head may be positioned adjacent the sheath at an angle of 60 degrees to 120 degrees with respect to a longitudinal axis of the sheath. The method may also include using at least one ink jet print head to print marking indicia on the sheath, the marking indicia indicating at least characteristic of the electrical cable assembly.