Corona Wire Aerosol Reducer for Inkjet Printers
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Solution Overview
Problem
Inkjet printers face issues with ink aerosol particles not reaching the print substrate, leading to deposits on the printer components, which affect print quality due to air currents and electrostatic forces, causing these particles to float and accumulate elsewhere within the printer.
Innovation Solution
The implementation of an ink aerosol reducer system using first and second corona wires of opposite polarities positioned on either side of the print heads to generate ions that capture and direct ink aerosol particles towards the print substrate, reducing their presence in the air and preventing accumulation on printer components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If inkjet printers direct droplets of liquid or dry ink toward a print substrate, then printing function is achieved, but ink aerosol particles are generated that do not reach the substrate and accumulate on printer components
Solution Approach 1:
The patent extracts and removes the harmful ink aerosol particles from the air within the printer using an aerosol management system. This system captures particles that would otherwise accumulate on printer components, separating the harmful aerosols from the printing process environment.
Solution Approach 2:
The patent converts the harmful ink aerosol particles into a beneficial state by charging them with electrostatic ions. The charged particles are then directed to the print substrate, transforming the waste aerosols into additional deposit material that can contribute to the printed image while preventing accumulation on components.
2Ease of operation
If air currents and electrostatic forces cause ink aerosol particles to float, then particles are distributed in air, but particles accumulate on printer components instead of reaching substrate
Solution Approach 1:
The patent replaces the mechanical/random distribution of ink aerosol particles by air currents with an electrostatic control system. By applying electrostatic charges to the particles, the system gains precise control over particle trajectories, directing them to the substrate rather than allowing random accumulation on components.
Solution Approach 2:
The patent changes the electrical charge parameter of the ink aerosol particles by introducing electrostatic ions. This parameter change transforms the particles from electrically neutral (subject to random air current movement) to electrically charged (subject to controllable electrostatic forces), enabling precise control over their deposition location.
3Quantity of substance
If ink aerosol particles accumulate on printer components, then deposits form on components, but print quality is affected
Solution Approach 1:
The patent implements a feedback mechanism where the aerosol management system continuously monitors and manages ink aerosol particles in real-time. By actively controlling particle charges and movements, the system prevents accumulation on components that would degrade print quality, maintaining consistent printing performance.
Solution Approach 2:
The patent introduces electrostatic ions as an intermediary substance between the ink aerosol particles and the print substrate. These ions charge the particles and mediate their transport, ensuring particles reach the substrate rather than accumulating on printer components, thereby maintaining print quality.
4Object-generated harmful factors
If corona wires of opposite polarities generate ions to capture ink aerosol particles, then particles are directed toward substrate, but charge buildup on non-conductive substrates may occur
Solution Approach 1:
The patent employs periodic alternation of corona wire polarities to manage charge deposition on the substrate. By switching between positive and negative ion generation in a controlled sequence, the system directs aerosol particles to the substrate while preventing excessive charge buildup that would distort subsequent droplet trajectories.
Solution Approach 2:
The patent makes the electrostatic field dynamic by allowing real-time adjustment of corona wire polarities and activation sequences. This dynamic control enables the system to adapt to substrate properties (conductive vs. non-conductive) and printing conditions, optimizing particle deposition while managing charge 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
This solution effectively reduces ink aerosol particles in the air, minimizing their impact on print quality by ensuring they land on the substrate, thereby maintaining the printer's performance and preventing charge buildup on non-conductive substrates that could distort ink droplet trajectories.
Implementation Method 1
an ink aerosol reducer system using first and second corona wires of opposite polarities positioned on either side of the print heads to generate ions that capture and direct ink aerosol particles
Implementation Method 2
electrostatic forces, causing these particles to float and accumulate elsewhere within the printer
Data Source
AI summary
Printers, methods, and apparatus to reduce aerosol are disclosed. An example apparatus to reduce aerosol includes a print head to generate droplets and aerosol, and to direct the droplets toward a print substrate, a first corona wire to generate first ions having a first electrical polarity to direct the aerosol toward the print substrate, and a second corona wire to generate second ions to direct the aerosol toward the print substrate, wherein the second ions have a second electrical polarity that is opposite the first electrical polarity.