Structured Passivation of Endless Strips via Digital Jet Printing
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Solution Overview
Problem
Existing methods for structured passivation of endless belts lack an integrated solution for optimal positioning of the nozzle head and light source, leading to inefficiencies and inaccuracies in the process, particularly when dealing with metallic endless belts stretched between deflection rollers.
Innovation Solution
The method involves applying a mask to the endless belt in the area of a deflection roller, with the nozzle head and light source strategically positioned to minimize vibrations and ensure accurate application, using a digital jet printing process and UV or infrared curing, respectively, while a material measure or position mark aids in compensating for belt length changes during processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the nozzle head and light source are positioned optimally for processing endless belts, then manufacturing precision and process efficiency are improved, but device complexity increases due to integrated positioning requirements
Solution Approach 1:
The patent combines the nozzle head for mask application and the light source for curing into an integrated processing unit that moves together along the endless belt. This merging of functions into a single coordinated system improves manufacturing precision by ensuring consistent relative positioning between application and curing operations, while the modular integrated design actually reduces overall device complexity compared to separate systems.
Solution Approach 2:
The patent employs a dynamic positioning system where the nozzle head and light source are mounted on a movable carrier that can be positioned at different locations along the endless belt. This dynamic arrangement allows optimization of processing parameters at each position while maintaining manufacturing precision through controlled movement, resolving the contradiction between precision and adaptability.
2Productivity
If mask application is performed on a moving endless belt, then productivity is improved, but measurement precision deteriorates due to belt motion and vibration
Solution Approach 1:
The patent incorporates a feedback system with sensors that continuously monitor the position and motion of the endless belt during mask application. This real-time feedback allows the control system to compensate for belt vibrations and motion variations, maintaining measurement precision while enabling continuous high-speed processing, thus resolving the contradiction between productivity and measurement accuracy.
Solution Approach 2:
The system performs preliminary positioning and calibration of the mask application parameters before the belt enters the processing zone. By pre-establishing reference positions and compensating for expected vibrations in advance, the system maintains measurement precision during continuous operation, allowing high productivity without sacrificing accuracy.
3Ease of operation
If the mask is applied and cured in separate steps, then ease of operation is improved, but loss of time increases due to additional handling and positioning
Solution Approach 1:
The patent merges the mask application and curing operations into a single integrated process step by positioning the light source immediately adjacent to the nozzle head on the same movable carrier. This eliminates intermediate handling and repositioning operations, reducing time loss while maintaining ease of operation through unified control of the combined system.
Solution Approach 2:
The system maintains continuous useful action by applying the mask and curing it in immediate succession without interruption or belt stopping. The integrated nozzle head and light source operate continuously as the belt moves through the processing zone, eliminating idle time and maintaining operational simplicity through uninterrupted processing.
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
This approach enables precise, continuous, and efficient structured passivation of endless belts with reduced need for adjustments, improved accuracy, and the ability to apply complex three-dimensional structures, enhancing the belt's durability and performance in applications like belt casting plants.
Implementation Method 1
The mask consists of a light-curable mask material or contains at least such components. After the mask has been applied, in a further step, the mask is at least partially irradiated using a light source suitable for curing.
Data Source
Figure 1~3
Figure 4~6
Figure 7~9
AI summary
The invention relates to a method for the structured passivation of an endless strip (2), in which the endless strip (2) is clamped between at least two deflection rollers (3, 4, 9, 10) and a mask for the structured passivation is applied on the endless strip (2) with the aid of a nozzle head/pressure head (5, 51, 52) in a digital jet printing method. The application of the mask is carried out in the region of a deflection roller (3, 4, 9, 10). In a further step, the mask which is at least partially made of a light-curable mask material is irradiated and cured with a curing-suitable light source (7). The invention also discloses an apparatus (1, 101..103) for carrying out the method.