Heated Pressure Roll Drying for Inkjet Prints With Less Curling

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Solution Overview

Problem

Existing inkjet printing systems are energy-intensive and produce excess heat, leading to paper curling and increased operational costs, while maintaining image quality.

Innovation Solution

A printing system utilizing a heated pressure roll assembly with a hydrophobic surface and optional release agent to dry ink images directly on the print media, reducing the need for conventional dryers and minimizing energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high powered infrared lamps are used to dry the ink, then the ink drying effectiveness is improved, but energy consumption increases and excess heat is produced

Engineering Contradiction:

Improveink drying effectivenessVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent replaces the infrared lamp heating system with a pressure roll mechanical system. The pressure roll applies direct pressure and mechanical force to the printed substrate, utilizing the friction and compression to achieve ink drying through absorption into the roll surface and subsequent transfer back to the substrate, eliminating the need for high-powered infrared heating lamps and reducing energy consumption.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the drying mechanism from thermal (infrared radiation) to mechanical (pressure and friction). By altering the fundamental parameter of the drying process from temperature-based to pressure-based, the system achieves effective ink drying without the excessive energy consumption and heat generation associated with infrared lamps.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If high powered infrared lamps are used to dry the ink, then the ink drying effectiveness is improved, but excess heat is produced leading to paper curling

Engineering Contradiction:

Improveink drying effectivenessVSAvoidexcess heat causing paper curling

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the potentially harmful effect of heat into a beneficial mechanical pressing action. Instead of using heat that causes paper curling, the system uses controlled mechanical pressure from the pressure roll to achieve the same drying effect without the harmful thermal side effects, thereby eliminating paper distortion.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If conventional infrared dryers are used, then ink drying is achieved, but the device footprint and complexity increase

Engineering Contradiction:

Improveink drying functionVSAvoiddryer system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the drying function with the existing pressure application mechanism in the printing system. By integrating the pressure roll that already exists for other printing functions to also perform the drying function, the system eliminates the need for separate infrared lamp assemblies, reflectors, and control systems, thereby reducing overall device complexity and footprint.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent makes the pressure roll multi-functional by having it serve both the traditional pressure application role and the new ink drying role. This universal application of the pressure roll eliminates the need for dedicated drying components, simplifying the overall system architecture and reducing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 system achieves clear, smudge-free prints with reduced energy usage and lower operational costs by enhancing evaporation through direct heat application, while maintaining image quality and reducing paper curling.

Implementation Method 1

applying heat to the wet ink image, including directly contacting the wet ink image with a rotating heated pressure roll

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

enhancing evaporation through direct heat application

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 3

A heated pressure roll assembly is described which includes a hydrophobic pressure roll surface

Methodology Applied

Scientific EffectHydrophobicity: Hydrophobe

Data Source

PatentUS20260061758A1Pressure-assisted drying for an ink jet printer

Publication Date: 2026.03.05 XEROX CORP

AI summary

A printing system and a method of printing are described. The printing system includes a source of print media, an inkjet marking device which applies ink images to the print media, and a dryer component which receives print media from the inkjet marking device. The dryer component includes a first dryer module, the first dryer module includes a rotating first roll and a biasing member. The first roll and the biasing member together define a nip through which the print media passes. An exterior surface of the first roll applies heat directly to the ink images to dry the ink images, at least partially.