Image-Mapped Hybrid Print Drying for Energy Control
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Solution Overview
Problem
High-speed inkjet printing faces challenges in optimizing energy consumption and reducing substrate warping due to inefficient energy application in ink drying, particularly in radiation drying methods like IR and UV curing, which lead to increased power consumption and substrate deformation.
Innovation Solution
A method that analyzes print images to optimize energy consumption and substrate orientation, combining IR/NIR lamps with rapid modulation technologies like LEDs or lasers, and adjusts energy application based on thermal inertia and ink distribution to minimize energy waste and warping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high energy dose is applied for fast drying at high printing speeds, then drying speed is improved, but power consumption increases and substrate warping occurs
Solution Approach 1:
The drying system is divided into multiple independent IR lamp zones along the substrate path. Each zone can be controlled separately to provide drying energy only where and when needed, rather than applying uniform high energy across the entire drying area. This segmentation allows the system to maintain high drying speed in ink-heavy areas while reducing energy consumption in areas with less ink.
Solution Approach 2:
The IR lamp zones are equipped with dynamic control systems that adjust their power output in real-time based on detected ink distribution and drying progress. This dynamic adjustment enables the system to optimize the balance between drying speed and energy consumption, applying higher energy only when and where required rather than maintaining constant high power consumption.
2Productivity
If high energy dose is applied for fast drying at high printing speeds, then drying speed is improved, but substrate warping increases
Solution Approach 1:
The drying system is divided into multiple independent IR lamp zones along the substrate path. Each zone can be controlled separately to provide drying energy only where and when needed, rather than applying uniform high energy across the entire drying area. This segmentation allows the system to maintain high drying speed in ink-heavy areas while reducing energy consumption in areas with less ink.
Solution Approach 2:
Different zones of the drying system apply different energy levels tailored to the local ink distribution and substrate condition. Areas with heavy ink coverage receive higher energy doses for rapid drying, while areas with light coverage receive lower energy to prevent substrate warping. This localized quality control maintains substrate flatness while achieving overall high drying speed.
3Ease of operation
If print jobs are processed without analyzing image content, then processing simplicity is maintained, but energy waste increases due to uniform high energy application
Solution Approach 1:
The system performs preliminary analysis of the image content and ink distribution before the actual drying process begins. This pre-analysis allows the control system to pre-calculate the optimal energy distribution across different zones, identifying areas that require high energy and areas where low energy suffices. This preliminary action enables energy optimization without adding complexity to the operational workflow.
Solution Approach 2:
The system incorporates feedback mechanisms that monitor the actual drying progress and substrate conditions in real-time. This feedback information is used to dynamically adjust the energy distribution across zones, ensuring that energy is applied efficiently according to actual needs rather than uniform high energy application. The feedback loop maintains processing simplicity while eliminating energy waste.
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
Significantly reduces energy consumption by up to 73%, minimizes substrate warping, and enhances printer performance by optimizing energy use and reducing greenhouse gas emissions.
Implementation Method 1
Infra-red (IR) drying methods are among the most used due to the high speed of printing required by digital printing. In infra-red drying, there are no mechanical effects such as jetted hot air or a heating belt which heats a substrate by conduction. IR radiation provides large amounts of energy in a short period of time. When the ink absorbs the energy it starts to heat up and, when it reaches a sufficiently high temperature, the water in the ink begins to evaporate
Implementation Method 2
When the ink absorbs the energy it starts to heat up and, when it reaches a sufficiently high temperature, the water in the ink begins to evaporate, thus allowing to the system to dry the ink in a short period of time
Implementation Method 3
combining IR/NIR lamps with rapid modulation technologies like LEDs or lasers
Implementation Method 4
combining IR/NIR lamps with rapid modulation technologies like LEDs or lasers
Implementation Method 5
IR radiation provides large amounts of energy in a short period of time. When the ink absorbs the energy it starts to heat up
Data Source
AI summary
A method is provided for optimizing print drying in which the printer analyzes an image to be printed. A source of energy used to cure/dry ink/primer each time the image is ready to be printed is determined, and a best orientation of the image is selected to optimize energy consumption and energy applied to the substrate. In an alternative method a drying profile corresponding to application of ink to the substrate is mapped to the image and, based on the mapping, power applied by an emitting radiation system to said substrate is adjusted. A further embodiment comprises a hybrid drying system that uses in combination an IR/NIR lamp and diodes or other sources of power that are rapidly modulated and have quick response times while exhibiting low thermal inertia.