Composite Dryer Transport Belt for Uniform Drying
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Solution Overview
Problem
Vacuum belts in printer dryers cause image quality defects due to thermal conductivity and vacuum gradients, resulting in visible circles and lines on printed items, especially with High Fusion and High Definition inks, as the solvents evaporate unevenly due to non-uniform thermal loading and belt perforations.
Innovation Solution
A multilayer, multi-material transport belt with low thermally conductive, air-permeable outer and inner layers made of entangled fiber fabrics laminated onto a stiffer, perforated or woven middle layer, which provides dimensional stability and avoids perforations, ensuring a uniform, flat surface for printing and preventing IQ defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a perforated vacuum belt is used for drying, then air permeability and vacuum function are improved, but image quality defects (circles and lines) appear due to thermal gradients
Solution Approach 1:
The belt is divided into multiple layers with distinct functions: the outer layer provides a non-perforated smooth surface for uniform thermal contact, while the inner layer contains the perforations for vacuum and air flow. This segmentation allows each layer to optimize its specific function without compromising the other.
Solution Approach 2:
The outer non-perforated layer acts as an intermediary between the heated belt and the print media, distributing thermal energy uniformly across the surface while the inner perforated layer handles air flow. This intermediary layer prevents direct thermal gradients at the media contact surface.
2Manufacturing precision
If a non-perforated flexible surface is used, then image quality is improved by preventing thermal gradients, but vacuum holding capability and air flow are reduced
Solution Approach 1:
The belt is divided into multiple layers with distinct functions: the outer layer provides a non-perforated smooth surface for uniform thermal contact, while the inner layer contains the perforations for vacuum and air flow. This segmentation allows each layer to optimize its specific function without compromising the other.
Solution Approach 2:
Different regions of the belt structure have different properties optimized for their specific functions: the outer surface is smooth and non-perforated for uniform heating, while the inner structure is perforated for air flow and vacuum. Each layer's local quality matches its functional requirement.
3Ease of manufacture
If a single-layer perforated belt is used, then manufacturing simplicity is maintained, but dimensional stability and belt life are reduced due to creasing and folding
Solution Approach 1:
The belt uses a composite structure combining a flexible outer layer with a dimensionally stable inner layer. This composite construction provides both the flexibility needed for operation and the dimensional stability to prevent creasing and folding, extending belt life while maintaining manufacturability.
Solution Approach 2:
The dimensionally stable inner layer acts as a cushioning support that prevents the flexible outer layer from creasing and folding during operation. This underlying support structure protects the belt from damage before it can cause permanent deformation or failure.
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 eliminates image quality defects by maintaining uniform drying and preventing creasing, folding, and bunching, while ensuring proper belt tracking and extended belt life through the use of a non-perforated, flexible surface and a stiffer substrate that allows air permeability.
Implementation Method 1
a heater positioned adjacent to the transport belt and configured to heat the printed item on the transport belt
Implementation Method 2
a vacuum plenum positioned adjacent to the transport belt and configured to draw air through the transport belt
Implementation Method 3
The outer layer provides a surface that applies a vacuum force to the print media being held on the transport
Data Source
AI summary
A printer is configured to apply marking material to print media to create a printed item, and a transport belt is positioned to receive the printed item from the printer and is configured to dry the marking material on the printed item. The transport belt has a middle layer attached between outer and inner layers, and the printed item contacts the outer layer. The outer and inner layers are non-perforated entangled fiber materials that are porous and that are more flexible than the middle layer.