Air Recirculator Assembly Forms Barrier in Image Forming Apparatus
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Solution Overview
Problem
Image forming apparatuses face contamination and component malfunctions due to aerosol and particulate deposition, which can cause image defects and reduce the lifespan of the equipment, as these particles form sticky masses and interact with other contaminants, leading to increased friction and optical sensor clouding.
Innovation Solution
An air recirculator assembly is integrated into the image forming apparatus to form an air barrier across the print zone, redirecting and filtering aerosols and particulates, and a maintenance mode is implemented where a second set of drops is ejected to maintain flow paths, preventing substrate contact with the fluid applicator unit and utilizing a service unit to collect aerosols and particulates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fluid applicator unit ejects drops on substrate, then image formation is achieved, but aerosol and particulate contamination occurs on substrate and components
Solution Approach 1:
The harmful aerosol and particulates are extracted from the air stream using a filter assembly positioned in the air barrier system. The filter actively removes contaminants while allowing the air barrier to maintain its protective function, separating the harmful elements from the useful air flow that prevents deposition.
Solution Approach 2:
A service unit with collection member is introduced as an intermediary to capture and collect aerosol and particulate matter before it can deposit on critical components. The collection member receives contaminants from the air stream and holds them for periodic disposal, acting as a mediator between the contamination source and the vulnerable components.
2Reliability
If aerosol and particulates are not removed, then contamination and component malfunctions occur, but implementing removal systems increases device complexity
Solution Approach 1:
The air barrier system performs multiple functions simultaneously: it prevents aerosol deposition on the substrate, directs contaminated air to the filter assembly, and maintains proper air flow patterns. The service unit also serves dual purposes by both collecting contaminants and guiding air flow through the filter, reducing the need for separate dedicated components.
Solution Approach 2:
The air recirculator assembly creates a self-sustaining system where air is continuously circulated, filtered, and reused. The service unit automatically collects contaminants without requiring external intervention, and the system maintains its own air quality through continuous recirculation and filtration, reducing the need for additional maintenance systems.
3Object-affected harmful factors
If air barrier is formed to redirect aerosol, then deposition on substrate is reduced, but aerosol may accumulate in the print zone
Solution Approach 1:
The air recirculator operates continuously to maintain the air barrier and simultaneously draw aerosol away from the print zone through the service unit. The continuous air flow prevents aerosol accumulation by constantly moving contaminants toward the collection member and filter, ensuring that the protective function never compromises the containment function.
Solution Approach 2:
The air barrier system creates a feedback loop where the air flow pattern continuously monitors and responds to aerosol presence. The recirculated air that has passed through the service unit and filter provides real-time feedback about contamination levels, automatically adjusting the air flow dynamics to maintain optimal protection without allowing accumulation.
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 air recirculator effectively reduces aerosol and particulate deposition on the substrate and components, preventing image defects and component malfunctions, and extending the lifespan of the image forming apparatus by maintaining clean conditions and reducing friction.
Implementation Method 1
The air recirculater assembly may direct air to form an air barrier across the print zone to redirect at least one of aerosol and particulates
Implementation Method 2
to filter the at least one of the aerosol and particulates to form filtered air
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
An image forming apparatus includes a substrate receiving member, a fluid applicator unit, and an air recirculator assembly. The substrate receiving member may selectively receive a substrate. The fluid applicator unit may selectively eject a first set of drops to the substrate received by the substrate receiving member in a print mode and a second set of drops in a maintenance mode. The air recirculater assembly may direct air to form an air barrier across the print zone to redirect at least one of aerosol and particulates from crossing through the air barrier and onto the substrate, to filter the at least one of the aerosol and particulates to form filtered air, and to form the air barrier with the filtered air.