Vinyl Mesh Bug Screens for Vivid Printing and Airflow

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Solution Overview

Problem

Existing soft bug screens with extruded coated yarn substrates face challenges with ink adhesion, color vibrancy, and waste ink management when printed using wide-format printers, leading to faded, uneven, and costly issues with latex-based inks, and solvent-based inks pose health risks.

Innovation Solution

Switching to vinyl coated mesh as a substrate, which allows for better ink adhesion and vibrancy, and using a release liner to reduce waste ink collection issues, along with adjusting printer settings to prevent substrate curling and ensure smooth printing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If extruded coated yarn substrate is used for soft bug screens, then the bug screen provides basic functionality, but ink adhesion is poor and color vibrancy is reduced

Engineering Contradiction:

Improveink adhesionVSAvoidcolor vibrancy

Core Design Contradiction:

StrengthVSIllumination intensity

Solution Approach 1:

The patent changes the substrate material parameters from extruded coated yarn to vinyl coated mesh, which has different surface properties that enable better ink adhesion and color vibrancy when printed with latex-based inks

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses vinyl coated mesh as a composite substrate material that combines the mesh structure for airflow with a vinyl coating surface that provides optimal ink reception properties for latex-based printing

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If latex-based inks are used for printing on extruded coated yarn, then worker safety is improved compared to solvent-based inks, but the printed images fade and waste ink collection becomes costly

Engineering Contradiction:

Improveworker safetyVSAvoidimage durability

Core Design Contradiction:

Object-affected harmful factorsVSDuration of action of stationary object

Solution Approach 1:

The patent changes the substrate surface characteristics to vinyl coated mesh, which creates optimal adhesion properties for latex-based inks, preventing fading and extending image durability while maintaining the safety benefits of water-based latex inks

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent reduces waste ink collection costs by improving print efficiency on vinyl coated mesh substrate, which minimizes ink waste and extends the operational life of printing components

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Adaptability or versatility

If wide-format printers are used to print on extruded coated yarn substrate, then graphics can be applied to bug screens, but the substrate curls and printing precision is reduced

Engineering Contradiction:

Improvegraphic application capabilityVSAvoidprinting precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent changes the substrate physical properties to vinyl coated mesh, which has dimensional stability that prevents curling during the wide-format printing process, ensuring precise graphic application

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent selects a substrate (vinyl coated mesh) that is pre-conditioned to resist curling, so that when the printing process begins, the substrate remains flat and stable throughout the printing operation

Inventive Principle:

Principle #10Preliminary action

4Ease of manufacture

If extruded coated yarn substrate is used, then basic bug screen functionality is provided, but waste ink collection is excessive and costly

Engineering Contradiction:

Improvebug screen productionVSAvoidwaste ink

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent changes the substrate surface properties to vinyl coated mesh, which improves ink transfer efficiency during printing, reducing the amount of waste ink generated during the manufacturing process

Inventive Principle:

Principle #35Parameter changes

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 vinyl coated mesh substrate provides durable, vivid, and long-lasting printed images on bug screens, reducing waste ink collection costs and improving worker safety by using latex-based inks, while maintaining airflow to prevent engine overheating.

Implementation Method 1

The vinyl coated mesh substrate provides durable, vivid, and long-lasting printed images on bug screens

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

using a release liner to reduce waste ink collection issues

Methodology Applied

Scientific EffectRelease liner barrier effect:

Implementation Method 3

maintaining airflow to prevent engine overheating

Methodology Applied

Scientific EffectMesh filtration and airflow: Filter (physical)

Data Source

PatentUS11850876B1Motor-vehicle soft bug screen products and production

Publication Date: 2023.12.26 BUXTON JESSE J

AI summary

Soft bug screens for shielding motor vehicle radiators are disclosed. Mesh material having an un-lined surface and a surface with release liner is selected. The mesh material is fed out as uncut sheet from a wide roll, which is conveyed through a wide format printer with the release liner crossing the “waste ink collector” and the un-lined broad surface transiting the ink-application system. A light vacuum suction is supplied to the release-liner lined surface, to smooth the sheet flat without suctioning the sheet down to a pinned down immobility. Ink is applied on the transiting-past unlined broad surface of the mesh material while continuing to supply the light vacuum. The ink is let or heated to dry on the continuing transiting unlined broad surface along while still continuing supply of the light vacuum. The final outline is trimmed out. The release liner is peeled off.