Pivotable Support Rack for Variable Thickness Mailpiece Printing
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Solution Overview
Problem
Conventional print modules for mailpiece inserters are limited in processing mailpieces of varying thickness, as they require a fixed clearance gap, making it impossible to print consecutive thin and thick mailpieces effectively.
Innovation Solution
A print module with a compliant conveyance system featuring a pivotable support rack and a continuous compliant deck that uses a combination of high-modulus spring steel and high-yield strength materials, along with a flexible vacuum manifold system, to accommodate mailpieces of varying thickness by adjusting the stiffness and flexibility to maintain proper registration and ink deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed clearance gap is used in conventional print modules, then the structure is simple and stable, but the device cannot process mailpieces of varying thickness
Solution Approach 1:
The support rack is designed to be pivotable rather than fixed, allowing it to dynamically adjust its position and the clearance gap between the print head assembly and conveyance system. This dynamic adjustment enables the processing of mailpieces with varying thickness while maintaining a relatively simple overall structure.
Solution Approach 2:
The clearance gap parameter is made variable through the pivotable support rack mechanism. By changing the angular position of the support rack, the clearance gap can be adjusted to accommodate different mailpiece thicknesses, thereby improving adaptability without requiring complete structural redesign.
2Adaptability or versatility
If the support rack is made rigid and fixed, then the manufacturing precision is high, but the device cannot accommodate variable thickness mailpieces
Solution Approach 1:
The pivotable support rack provides a controlled dynamic adjustment mechanism that maintains precise registration while accommodating thickness variations. The pivoting action allows systematic adjustment of the clearance gap while keeping the print head assembly properly positioned relative to the mailpiece.
Solution Approach 2:
The support rack is pre-configured with pivot points and locking mechanisms that enable quick adjustment to the appropriate clearance gap before processing different thicknesses of mailpieces, ensuring precision is maintained without requiring complex real-time adjustments.
3Adaptability or versatility
If a pivotable support rack is implemented, then the device can process variable thickness mailpieces, but the device complexity increases
Solution Approach 1:
The pivotable support rack introduces minimal dynamic elements compared to the alternative of completely rigid or actively controlled systems. The simple pivoting motion with mechanical locking provides the necessary adaptability while keeping the overall device complexity manageable.
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 the efficient processing of mailpieces with varying thickness dimensions, ensuring smooth conveyance and precise ink deposition, thereby increasing throughput and maintaining print quality.
Implementation Method 1
A pair of gas springs produces a moment about a pivot axis to bias the support rack to an open position
Implementation Method 2
The vacuum conveyance/manifold system develops a pressure differential across each of the mailpieces to urge each mailpiece into frictional engagement with one or more conveyor belts
Implementation Method 3
urge each mailpiece into frictional engagement with one or more conveyor belts
Data Source
AI summary
A print module for printing mailpieces comprises a print head assembly operative to deposit ink on each mailpiece and a registration plate for registering a first surface of each of the mailpieces during print operations. The print module includes a conveyor belt opposing the registration plate and engaging a second surface of each of the mailpieces for conveyance along a feed path. Disposed beneath and supporting an underside surface of the conveyor belt, is a continuous compliant deck operative to urge the conveyor belt and mailpieces toward the registration plate during printing. The compliant deck is also operative to print consecutive mailpieces of variable thickness dimension. The print module also includes a pivotable support rack for mounting the print head assembly to a housing. A pair of gas springs produces a moment about a pivot axis to bias the support rack to an open position and a pair of locking mechanisms produces a biasing moment opposing the moment produced by the gas springs to retain the support rack in a closed position.