Multiple Zone Vacuum Table for Non-Planar Media Flatness
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Solution Overview
Problem
Current single-pass printing systems cannot effectively hold non-planar media types and thicknesses within a given flatness range, which hinders high definition printing due to bowed or irregularly shaped substrates like paper, paperboard, and corrugated cardboard.
Innovation Solution
A printer vacuum table with multiple zones, including both fixed and variable vacuum zones, is used to apply controlled vacuum to constrain media, ensuring consistent flatness by enabling or disabling zones based on media size and position, and varying the vacuum pressure to compensate for non-planar features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single vacuum table is used, then the structure is simple, but it cannot hold non-planar media within a given flatness range
Solution Approach 1:
The vacuum table is divided into multiple independent vacuum zones (first vacuum zone, second vacuum zone, third vacuum zone, etc.) that can be independently controlled. Each zone applies vacuum to specific regions of the media, allowing differential pressure control across the media surface to compensate for non-planar features like bows and irregularities, thereby achieving the required flatness range for high definition printing.
Solution Approach 2:
Different vacuum zones apply different vacuum levels to different locations on the media based on local flatness requirements. The system selectively enables or disables specific vacuum zones and adjusts their vacuum pressure independently to address local non-planar features, ensuring each region of the media achieves the desired flatness for printing.
2Manufacturing precision
If vacuum pressure is increased to hold non-planar media, then flatness control improves, but media leakage increases
Solution Approach 1:
By segmenting the vacuum table into multiple zones with independent control, the system can apply high vacuum pressure to specific zones where non-planar features require additional holding force, while maintaining lower or zero vacuum in other zones where media is already flat. This prevents excessive vacuum from causing leakage or damage to media in regions that don't require it.
Solution Approach 2:
The system dynamically adjusts vacuum pressure parameters in different zones based on real-time detection of media flatness and position. Vacuum pressure is increased only in zones where non-planar features are detected, and decreased or disabled in zones where media is already within the acceptable flatness range, maintaining reliable hold-down without causing leakage.
3Adaptability or versatility
If multiple vacuum zones are implemented, then flatness control for various media types improves, but system complexity increases
Solution Approach 1:
The vacuum table is segmented into multiple independently controllable vacuum zones, each capable of being selectively enabled or disabled. This segmentation allows the system to adapt to different media types, sizes, and non-planar features by activating only the necessary zones, providing versatility without requiring complete system reconfiguration for each media type.
Solution Approach 2:
The vacuum zone control system is designed to be dynamic, with zones that can be selectively enabled or disabled based on media characteristics. The system automatically adjusts which vacuum zones are active and at what pressure levels, providing adaptability to various media types while managing complexity through automated control rather than manual reconfiguration.
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 solution allows for high definition printing on a variety of media types and thicknesses with non-planar features by maintaining a controlled flatness range, ensuring consistent vacuum hold-down and preventing leakage, even with smaller capacity blowers.
Implementation Method 1
A printer vacuum table with multiple zones, including both fixed and variable vacuum zones, is used to apply controlled vacuum to constrain media
Data Source
AI summary
Disclosed are printer vacuum tables, and corresponding systems and methods for their use, in which the printer vacuum tables include multiple zones to apply vacuum, to hold a variety of media types and thicknesses within a given flatness range, to allow high definition printing. The vacuum zones run in the print direction, and each can be controlled for vacuum on and off. In an illustrative embodiment, the vacuum zones include one or more vacuum zones that are fixed with respect to a printer vacuum table surface, and one or more variable vacuum zones that are movable with respect to the printer vacuum table surface. One or more of the vacuum zones can be turned off if the print media does not cover the zone, such as to prevent leakage, and to provide more consistent vacuum hold down, regardless of media size or width.