Flow Valve Airflow Split for Dryer Temperature Control
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Solution Overview
Problem
Inkjet printers face challenges in efficiently varying the energy used for drying media due to slow response times of heating elements and inefficiencies in power supply when different pages require different drying energies, as existing methods struggle to quickly adjust air temperature and airflow rate.
Innovation Solution
An apparatus and method utilizing a flow valve to control the ratio of airflow between a heating duct and a bypass duct, allowing for rapid adjustment of air temperature by directing more airflow through the heating duct for higher temperatures and more through the bypass duct for lower temperatures, using a constant temperature heating element and maintaining constant airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the power to the heating element is varied to change air temperature, then the air temperature can be adjusted, but the response time is slow and the power supply operates at lower efficiency
Solution Approach 1:
The air flow path is divided into two separate ducts: a heating duct that passes through the heating element and a bypass duct that does not. A flow valve controls the distribution of air between these two ducts, allowing independent control of temperature without varying power to the heating element, thus achieving fast response time.
Solution Approach 2:
A flow valve is introduced as an intermediary device to control the split between heating duct and bypass duct. This mediator enables rapid adjustment of air temperature by changing the flow distribution ratio, eliminating the slow response time associated with varying heating element power.
2Temperature
If the power to the heating element is varied to change air temperature, then the air temperature can be adjusted, but the power supply operates at lower efficiency when not at maximum power
Solution Approach 1:
The system segments the air flow into heated and unheated paths, allowing the heating element to operate at constant maximum power while the flow valve controls the actual temperature output by adjusting the proportion of air going through the heating duct versus the bypass duct, thereby maintaining power supply efficiency.
Solution Approach 2:
Instead of changing the power parameter to the heating element, the system changes the flow distribution parameter using the flow valve. This allows the heating element to operate continuously at optimal power levels while the temperature is controlled by varying the flow split ratio between the two ducts, eliminating energy loss from inefficient power supply operation.
3Use of energy by moving object
If the airflow rate is varied to change energy supplied to media, then the energy can be adjusted, but the response time is slow
Solution Approach 1:
The air flow path is segmented into heating and bypass ducts, allowing the total airflow rate to be maintained constant while the heating duct receives a variable portion of the flow controlled by the flow valve. This enables rapid adjustment of effective heating energy without the slow response time associated with varying overall airflow rate.
4Temperature
If a variable temperature heating element is used, then air temperature can be adjusted, but the heating element cannot quickly cool down
Solution Approach 1:
The system separates the heating function from the air flow control by using a flow valve to direct air to either the heating duct or bypass duct. This allows the heating element to maintain a constant temperature without being forced to cool down when temperature reduction is needed, as air can simply be diverted through the bypass duct, eliminating the slow cooling time problem.
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
Enables quicker and more precise control of air temperature, reducing energy waste and improving efficiency by allowing the use of a constant temperature heating element, such as a PTC heating element, and maintaining consistent airflow, thereby optimizing energy use across varying page types.
Implementation Method 1
The heating duct contains a heating element... To increase the air temperature at the outlet of the dryer more of the total airflow is directed through the beating duct
Implementation Method 2
a flow valve that changes the ratio of airflow between a heating duct and a bypass duct... The ratio of air is changed by adjusting the flow valve that controls the amount of airflow into the two ducts
Data Source
Figure 1
Figure 2A~2C
Figure 3
AI summary
.A heater assembly is disclosed. The heater assembly has a frame that has a first and a second opening. There is a heater element located in the first opening. A flow valve is mounted to the frame and movable from a first position to a second position. In the first position, the flow valve blocks airflow through the first opening. In the second position, the flow valve blocks airflow through the second opening. When the flow valve is between the first and second position the flow valve blocks at least some airflow through the first opening and blocks at least some airflow through the second opening.