Conductive Plastic Ionizer for Uniform Charge Distribution

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Solution Overview

Problem

Conventional ionizing devices for charging objects are susceptible to environmental variations, suffer from uneven charge distribution, and have issues with pin erosion and contamination, while devices for static charge dissipation are needed to prevent equipment damage and operator safety hazards.

Innovation Solution

A method and device using conductive plastic with uniform resistance, applied with high voltage, for charging or neutralizing static charges on objects, which can be integrated into existing equipment and provides a consistent ion field.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional ionizing devices with pins are used to charge objects, then charge application is achieved, but pin erosion and contamination occur leading to uneven charge distribution and equipment malfunction

Engineering Contradiction:

Improvecharge application consistencyVSAvoidpin erosion and contamination

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent removes the pins entirely from the charging device, replacing them with a pinless ionizing chamber that generates ions directly in the air stream. This extraction of the problematic pins eliminates the source of erosion and contamination while maintaining the charge application function through alternative means (ion generation without physical contact points).

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical pin-based ion generation system with an electrical field-based ionizing chamber. Instead of using physical pins that erode, the system uses high voltage electrodes within a sealed chamber to generate ions electrically, substituting a mechanical system with an electrical field-based system that has no moving or consumable parts.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If conventional pin-based ionizing devices are used, then charge distribution is achieved, but environmental variations (temperature, humidity, turbulence) affect the charge uniformity

Engineering Contradiction:

Improvecharge distribution uniformityVSAvoidsensitivity to environmental variations

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent creates a controlled, sealed ionizing chamber environment that isolates the ion generation process from external environmental variations. The chamber acts as an inert environment where temperature, humidity, and air turbulence have minimal impact on charge distribution, as the ion generation occurs within this protected space rather than directly in the ambient air stream.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The patent pre-charges insulative members by placing them in contact with or proximity to the charged conductive plastic before these members are used in the manufacturing process. This preliminary charging action ensures that the objects receive a consistent charge baseline before entering subsequent processing steps, reducing the impact of environmental variations during later stages.

Inventive Principle:

Principle #10Preliminary action

3Duration of action of stationary object

If pins are made from harder materials to prevent erosion, then pin durability is improved, but pin material merely slows rather than prevents erosion and cost increases

Engineering Contradiction:

Improvepin service lifeVSAvoidmanufacturing cost and complexity

Core Design Contradiction:

Duration of action of stationary objectVSEase of manufacture

Solution Approach 1:

The patent eliminates the need for expensive, hard materials by removing pins entirely. The pinless ionizing chamber uses sealed, non-consumable electrodes that generate ions without physical contact, effectively replacing expensive durable pins with a lower-cost sealed chamber design that has no disposable components. The system achieves indefinite service life without requiring expensive pin materials.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 applies or dissipates charges without environmental interference, ensuring consistent and safe operation, reducing equipment malfunction and safety risks.

Implementation Method 1

A high voltage is applied to a conductive plastic having a uniform resistance throughout. Insulative material is placed in proximity to, or in contact with, the conductive plastic, thereby charging the insulative material.

Methodology Applied

Scientific EffectElectrostatic induction: Electrostatic Induction

Implementation Method 2

conventional ionizing devices utilize one or more rows of pins to introduce ions into the surrounding gas (such as air) and form a layer on one side of an object

Methodology Applied

Scientific EffectIon generation: Ionisation

Data Source

PatentUS8559156B2Method and apparatus for charging or neutralizing an object using a charged piece of conductive plastic

Publication Date: 2013.10.15 ILLINOIS TOOL WORKS INC

AI summary

A method of charging insulative material includes applying a high voltage to a conductive plastic having a uniform resistance throughout. Insulative material is placed in proximity to, or in contact with, the conductive plastic, thereby charging the insulative material. Further, a device for placing charge on an object proximate to the device includes a conductive plastic having a uniform resistance throughout. A high voltage power supply has an output coupled to the conductive plastic.