Direct Printing on Corrugated Metal-Clad Cable with UV Curing
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Solution Overview
Problem
Existing methods for marking metal clad cables, such as tapes, painting, and etching/embossing, face issues like adhesion loss, smudging, and high equipment costs, making them unreliable and inefficient.
Innovation Solution
A direct printing apparatus and method using UV curable ink with entrance, lower, and exit rollers, printheads, and a UV curing station to apply and cure markings on corrugated metal clad cables, ensuring clear and durable markings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If physical tapes are affixed to the cable armor, then markings are provided on the cable, but the markings can inadvertently fall off when cables are manipulated
Solution Approach 1:
The patent replaces the mechanical tape affixing system with a direct printing system that applies ink directly to the cable armor. This eliminates the physical tape layer and its adhesion problems, using instead a printing mechanism that deposits marking material directly onto the cable surface where it becomes permanently integrated with the armor.
2Reliability
If paint is applied directly on the cable armor, then permanent marking is provided, but the paint may not dry properly and may smudge or smear
Solution Approach 1:
The patent changes the physical-chemical parameters of the marking material by using UV-curable ink that transitions from a liquid state during application to a solid state upon UV exposure. This parameter change (from liquid to solid through photopolymerization) allows the marking to be applied in a workable state and then immediately locked into place, preventing smudging while maintaining permanence.
Solution Approach 2:
The patent applies the marking material to the cable armor in advance, and then immediately follows with UV curing to lock the marking in place before the cable undergoes any manipulation. This preliminary action of curing the ink before subsequent handling prevents the smudging problem that occurs when paint is applied but not properly dried before use.
3Reliability
If etching or embossing is used to mark the armor, then durable markings are provided, but specialized equipment is required which adds costs and time
Solution Approach 1:
The patent replaces the mechanical etching/embossing system with a printing system that uses printheads to deposit marking material on the cable armor. This substitution eliminates the need for complex specialized equipment while achieving comparable or superior marking durability through the use of UV-curable ink that bonds to the armor surface.
Solution Approach 2:
The patent uses a printing-based marking system that is simpler and less expensive than etching or embossing equipment. The printing system can be implemented with standard printing components rather than specialized heavy equipment, reducing both capital costs and maintenance requirements while providing durable markings.
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
Provides clear, durable, and industry-standard markings on metal clad cables without smudging or smearing, reducing equipment costs and maintenance.
Implementation Method 1
A UV curing station downstream of a last of the series of printheads
Data Source
AI summary
An apparatus and method for direct printing on corrugated metal clad cable. The apparatus includes an entrance having one or more entrance rollers, a set of lower rollers, a series of printheads near the entrance, a UV curing station downstream of the printheads, one or more exit rollers, a print controller and a series of ink tanks. The entrance and exit rollers maintain the cable in proper position and alignment for the printheads. The method for printing provides for clear and legible printing on the cable.