Liquid Nitrogen Jet Stream Substrate Processing
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Solution Overview
Problem
Current cutting technologies for printing and packaging materials, such as mechanical die cutters and laser systems, face limitations in handling thick substrates, require significant setup and maintenance, and are costly; fluid jet cutters can cut thick materials but struggle with maneuverability and scoring folding lines effectively.
Innovation Solution
A jet system utilizing a nozzle that directs a stream of liquid nitrogen for cutting and scoring, with a modulator unit to control the jet stream, allowing for efficient cutting and folding of thick corrugated cardboard without mechanical stress and enabling fast processing of multiple layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical die cutters with cutting and scoring blades are used to cut and shape printing and packaging materials, then cutting and scoring functionality is achieved, but the system requires significant setup time, maintenance, and is costly for thick substrates
Solution Approach 1:
The patent replaces mechanical cutting and scoring blades with a fluid jet system that uses pressurized fluid to erode and cut the substrate material. This substitution eliminates the need for physical contact between cutting edges and the substrate, thereby reducing setup time for blade changes and maintenance while maintaining cutting and scoring functionality.
Solution Approach 2:
The patent changes the operational parameters by using variable fluid pressure and jet direction control to adapt the same system for different cutting and scoring tasks. By adjusting fluid pressure and nozzle orientation, the system can handle various substrate thicknesses and cutting requirements without requiring physical reconfiguration of mechanical blades.
2Adaptability or versatility
If mechanical die cutters with multiple blades are used to handle different cutting and folding tasks, then versatility is improved, but device complexity and maintenance requirements increase
Solution Approach 1:
The patent implements a universal fluid jet system where a single nozzle can perform multiple functions including cutting, scoring, and shaping by adjusting fluid pressure and jet angle. This multi-functional approach replaces the need for multiple specialized mechanical blades, thereby reducing device complexity while maintaining versatility in handling different cutting and folding tasks.
Solution Approach 2:
The patent introduces dynamic control of the fluid jet system, allowing real-time adjustment of jet direction, pressure, and modulation during operation. This dynamic adaptability enables the system to switch between different cutting and scoring modes without physical reconfiguration, reducing the complexity associated with fixed mechanical blade setups.
3Strength
If fluid jet cutters are used to cut thick materials, then the ability to handle thick substrates is improved, but maneuverability and scoring capability are reduced
Solution Approach 1:
The patent employs dynamic modulation of the fluid jet, allowing rapid changes in jet intensity, direction, and duration. This dynamic control enables precise maneuverability for scoring operations and selective application for cutting thick substrates, overcoming the limitation of static fluid jet systems that lack operational flexibility.
Solution Approach 2:
The patent utilizes periodic modulation of the fluid jet, switching between high-intensity pulses for cutting thick materials and lower-intensity continuous streams for scoring. This periodic action pattern allows the system to alternate between different operational modes, maintaining both the ability to cut thick substrates and the maneuverability required for scoring operations.
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 system achieves efficient cutting and scoring of thick corrugated cardboard with minimal maintenance and cost, allowing for the production of rigid boxes with strong walls and reducing wear on equipment, while maintaining high processing speed and precision.
Implementation Method 1
directing a jet stream of liquid nitrogen to the at least one sheet of paper, cardboard or carton
Implementation Method 2
the jet stream quickly evaporates without leaving any residue
Data Source
AI summary
The present disclosure relates to processing a substrate including at least one sheet of paper, cardboard or carton by directing a jet stream of liquid nitrogen to a surface of the substrate via a jet nozzle; and by moving the jet nozzle at a distance from the surface. The jet stream can be unmodulated or modulated. For example, the jet stream can be modulated by a modulation unit such as to reduce the impact of the jet stream on the surface. In this way, the jet stream can be applied to score folding lines into the substrate. An unmodulated or on/off modulated jet stream can be applied to cut lines into the substrate. Thus, by applying an appropriate modulation to the jet stream, the processing can switch between cutting the substrate and scoring folding lines into the substrate.