Variable Density Suction Cup Sheet for Corrugated Cardboard Hold-Down
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Solution Overview
Problem
Large format inkjet printers face difficulties in holding down corrugated cardboard flat during printing due to insufficient hold-down forces, often requiring more expensive materials to achieve high-quality prints.
Innovation Solution
A media support system utilizing a sheet of suction cups with varying densities, including elongated suction cups, is integrated with existing vacuum tables to increase hold-down forces and reduce vacuum leakage, allowing for high-quality printing on regular corrugated cardboard.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If high capacity vacuum pumps are used to develop hold down forces, then the hold down force is improved, but the cost and complexity of the system increases
Solution Approach 1:
The vacuum table surface is segmented into multiple zones with different suction cup densities. High-density zones provide stronger hold-down forces for areas requiring flat contact, while low-density zones reduce vacuum leakage and allow for media irregularities. This segmentation allows the system to achieve effective hold-down forces without requiring high capacity vacuum pumps, thereby reducing system complexity and cost.
Solution Approach 2:
Different regions of the vacuum table are assigned different suction cup densities based on local requirements. Areas where media flat contact is critical have higher suction cup density, while peripheral or less critical areas have lower density. This local differentiation optimizes hold-down force distribution and reduces overall vacuum demand, avoiding the need for expensive high-capacity pumps.
2Force
If high capacity vacuum pumps are used, then hold down force is improved, but energy consumption increases
Solution Approach 1:
The vacuum table is divided into zones with varying suction cup densities. This segmentation allows the system to concentrate vacuum force only where needed for media contact, rather than applying uniform high vacuum across the entire surface. Consequently, hold-down force is maintained in critical areas while overall energy consumption is reduced.
Solution Approach 2:
Instead of applying full vacuum strength uniformly across the entire table, the system uses partial vacuum action in low-density zones and excessive (stronger) vacuum action only in high-density zones where media contact is required. This selective application of vacuum force reduces energy consumption while maintaining adequate hold-down force.
3Ease of manufacture
If uniform density suction cups are used, then manufacturing is simplified, but vacuum leakage increases
Solution Approach 1:
The suction cup density varies by location on the vacuum table. High-density zones are positioned where media flat contact is essential, providing strong localized hold-down forces that prevent vacuum leakage. Low-density zones are placed in areas where media contact is less critical, reducing overall vacuum demand and leakage. This local differentiation maintains manufacturing feasibility while significantly reducing vacuum leakage.
4Force
If elongated suction cups are used, then hold down force is improved, but device complexity increases
Solution Approach 1:
Elongated suction cups are selectively deployed in high-density zones where enhanced hold-down force is required for optimal media contact. Circular suction cups are used in low-density zones where moderate holding force suffices. This localized use of elongated cups provides the necessary force enhancement without requiring all suction cups to be complex elongated shapes, thereby limiting the increase in overall device complexity.
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 solution effectively enhances hold-down forces, enabling high-quality inkjet printing on regular corrugated cardboard without the need for more expensive materials, while being compatible with existing printers through retrofitting.
Implementation Method 1
Large format inkjet printers use vacuum tables to hold down foamboard, cardboard and other inflexible or semi-flexible print media for printing. High capacity vacuum pumps are used to develop the hold down forces needed to keep large sheets of such media flat during printing.
Implementation Method 2
the media support uses a sheet of suction cups overlaid on a vacuum table to increase the hold down force applied to corrugated cardboard and other print media
Data Source
AI summary
In one example, a media support includes a sheet of elongated suction cups. In another example, a media support includes an arrangement of elongated and/or circular suction cups in which the density of the suction cups varies between different parts of the support.