Flat Dielectric Infrared Radiator for Printing Press Drying
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Solution Overview
Problem
Infrared drying systems in printing presses face challenges with slow response times and inefficiencies in drying solvent-based and water-based inks due to the need for active cooling and mismatched emission wavelengths, leading to overheating and reduced drying speed and homogeneity.
Innovation Solution
A flat infrared radiator with a dielectric heating element and a precious metal-containing conductor track emits medium-wave radiation, allowing for a closer distance to the printing material and eliminating the need for active cooling, while maintaining high power density and uniform radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If high electrical power infrared emitters are used, then response time is reduced and drying speed is improved, but emission wavelength shifts away from optimal water absorption and substrate overheating occurs
Solution Approach 1:
The patent changes the material parameter of the infrared emitter from conventional quartz glass to a polymer membrane with specific infrared transmission properties. This material substitution allows the emitter to operate at high temperatures with fast response time while maintaining optimal emission wavelength matching water absorption characteristics, preventing substrate overheating.
2Stability of the object's composition
If conventional quartz tube infrared emitters are used, then structural stability is maintained, but thermal mass is high and response time is slow
Solution Approach 1:
The patent replaces the thick quartz tube structure with a thin polymer membrane structure. The membrane has sufficient mechanical stability to contain the heating element while its thin construction dramatically reduces thermal mass, enabling fast thermal response time of less than 1 second while maintaining structural integrity during operation.
3Stability of the object's composition
If infrared emitter distance from substrate is increased, then homogeneous radiation is achieved, but radiation intensity decreases and drying time increases
Solution Approach 1:
The polymer membrane enables the emitter to be positioned much closer to the substrate than conventional emitters. The membrane's flexibility and thermal properties allow safe operation at distances of 5-20mm, maintaining homogeneous radiation distribution while significantly increasing radiation intensity and reducing drying time.
4Temperature
If active cooling is applied to infrared emitters, then emitter temperature control is improved, but drying efficiency is reduced due to cooling air interference
Solution Approach 1:
The polymer membrane emitter is designed to operate without active cooling systems. The membrane material inherently manages thermal conditions through its thermal properties, allowing the emitter to self-regulate temperature during high-power operation. This eliminates the need for cooling air flows that would otherwise interfere with the drying process and reduce productivity.
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 configuration achieves faster and more homogeneous drying with reduced waste and energy efficiency, ensuring high-quality printing by optimizing the emission spectrum and reducing thermal lag and overheating risks.
Implementation Method 1
a conductor track made of an electrically conductive, precious metal-containing resistance material is applied to a contact surface of the base body, which is connected to an electrical contact of an adjustable current source
Implementation Method 2
heating the heating element, heating the heating element material, causes the heating element material to emit infrared radiation
Implementation Method 3
Physical drying processes involve the evaporation of solvents and their diffusion into the substrate
Implementation Method 4
For water-based printing inks, it is desirable that the emission main wavelength of the infrared emitters matches the absorption characteristics of the water
Data Source
Figure 1~2
Figure 3~4
Figure 5~6(b)
AI summary
Known printing presses are equipped with a printing unit for applying solvent-containing printing ink to a printing material, and a transport device for transporting the printing material from the printing unit to a dryer unit which comprises at least one infrared radiator for drying the printing material. In order, proceeding herefrom, to provide a printing press with a dryer device which is improved for the drying of solvent-containing and, in particular, water-based printing ink with regard to homogeneity and rapidity of the drying, and in which the dryer unit manages without active cooling of the infrared radiator, it is proposed according to the invention that the infrared radiator is configured as a flat heating element that is made from a dielectric heating element material which emits infrared radiation upon heating and that has a heating surface which faces the printing material to be dried and a contact surface, on which a heating conductor track is applied, which heating conductor track is made from an electrically conducting resistance material containing precious metals and is connected with an electric contact to an adjustable power source.