Flared-Bore Vacuum Plate for Faster Sheet Handling Manufacture
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Solution Overview
Problem
Existing vacuum plate systems for handling sheet materials are limited by the weight and manufacturing cost of vacuum plates, particularly due to the time-consuming process of drilling numerous small holes for vacuum suction, which affects speed and efficiency in manufacturing processes.
Innovation Solution
A vacuum plate design featuring flared entrance bores with raised rims and a modular construction using a honeycomb reinforcement structure, allowing for faster and more efficient manufacturing through punching rather than drilling, and minimizing weight while maintaining effective vacuum suction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional drilling methods are used to create vacuum holes in the plate, then the holes can be formed with sufficient precision, but the manufacturing time and cost increase significantly
Solution Approach 1:
The patent replaces the traditional drilling mechanical system with a punching system. The punching process uses a punch tool that physically forces material through a die to create holes, rather than removing material through drilling. This substitution dramatically reduces manufacturing time while maintaining adequate hole precision for vacuum application.
Solution Approach 2:
The patent changes the manufacturing parameters by using punching instead of drilling. This involves changing the material removal mechanism from rotational cutting to compressive forcing through a die. The parameter change from drilling to punching enables faster production while achieving sufficient hole quality for the vacuum plate application.
2Strength
If the plate uses a solid construction for strength, then structural integrity is maintained, but the weight increases reducing handling efficiency
Solution Approach 1:
The patent applies local quality by using a honeycomb structure that provides strength where needed while reducing weight overall. The honeycomb pattern creates localized reinforcement through its geometric configuration, distributing loads efficiently across the plate structure. This allows the plate to maintain structural integrity for vacuum handling while significantly reducing weight compared to a solid construction.
Solution Approach 2:
The patent employs a composite structure combining the plate material with a honeycomb reinforcement pattern. This composite approach integrates two structural concepts: the base plate material providing surface integrity and the honeycomb pattern providing internal reinforcement. The combination achieves optimal strength-to-weight ratio for the vacuum plate application.
3Ease of manufacture
If vacuum holes are made with straight cylindrical bores, then manufacturing is simpler, but airflow efficiency and suction force are reduced
Solution Approach 1:
The patent applies curvature by forming the bore entrance with a flared or bell-shaped profile instead of a straight cylindrical shape. This curved geometry at the entrance facilitates smoother airflow into the bore, reducing turbulence and improving vacuum suction efficiency. The flared entrance acts as a transition zone that guides air flow more effectively into the hole.
Solution Approach 2:
The patent changes the bore geometry parameters from a simple cylindrical shape to a flared entrance configuration. This parameter modification involves altering the bore profile to include an expanded entrance section. The geometric parameter change improves airflow characteristics and suction force while remaining compatible with the punching manufacturing process.
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
The design significantly reduces manufacturing time and cost, enhances suction force, and improves airflow efficiency, enabling faster and more economical production of vacuum plates with improved lifting capabilities.
Implementation Method 1
at least one air outlet for connection to a source of vacuum pressure for applying a vacuum pressure to said bore from the second side of the first wall whereby the first wall provides, in use, a vacuum surface for pulling and holding said article to the vacuum surface
Data Source
AI summary
A vacuum plate which may be used in a system in which sheet material articles are handled by a vacuum plate. The vacuum plate comprises a first wall, a plurality of bores in the first wall, and at least one air outlet for connection to a source of vacuum pressure for applying a vacuum pressure to the bores. The first wall provides, in use, a vacuum lifting surface for pulling and holding the sheet material article to the vacuum surface when vacuum pressure is applied to the bores. Each bore comprises a flared opening terminating at the vacuum surface for admitting air pulled through the bore by the applied vacuum pressure, and opposite this opening, an exit for the air pulled through the bore, this exit being surrounded by a rim that extends above a surrounding surface of the second side of the first wall.