Induction Ink Melter with Dual Chamber Pressure System
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Solution Overview
Problem
Existing inkjet printers that use solid phase change ink struggle with efficient melting processes, requiring more energy and time to convert solid ink into a liquid state suitable for printing, which affects the printing efficiency and ink adhesion.
Innovation Solution
A melting device with a ferrous housing and induction heating mechanism, utilizing alternating current to generate electromagnetic fields that heat the ink, combined with a pressure system to manage ink flow and temperature, ensuring efficient melting and maintenance of the ink in a liquid state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional heating methods are used to melt phase change ink, then the ink can be melted, but the process requires excessive energy and time
Solution Approach 1:
The patent replaces conventional thermal conduction heating with electromagnetic induction heating. The induction heating system uses a magnetic field generated by a coil to directly induce eddy currents in the ferrous housing, which generates heat internally without direct thermal contact. This substitution of heating mechanism dramatically reduces energy consumption and melting time while maintaining effective ink melting.
Solution Approach 2:
The patent utilizes the phase transition properties of phase change ink by maintaining it in a liquid state through controlled melting. The induction heating system efficiently manages the solid-to-liquid phase transition of the ink, ensuring it remains in the appropriate state for printing while minimizing energy input required for the transition.
2Productivity
If conventional heating methods are used to melt phase change ink, then the ink can be melted, but the process takes excessive time
Solution Approach 1:
The patent replaces conventional thermal conduction heating with electromagnetic induction heating. The induction heating system uses a magnetic field generated by a coil to directly induce eddy currents in the ferrous housing, which generates heat internally without direct thermal contact. This substitution of heating mechanism dramatically reduces energy consumption and melting time while maintaining effective ink melting.
Solution Approach 2:
The ferrous housing is designed to be pre-heated by the induction heating system before ink is introduced or during ink loading. This preliminary heating action ensures that the housing and internal components are already at the required temperature when phase change ink is added, eliminating the need for extended heating cycles and reducing overall processing time.
3Volume of moving object
If a compact melting device is designed, then device size is reduced, but heating efficiency may be compromised
Solution Approach 1:
The patent replaces conventional thermal conduction heating with electromagnetic induction heating. The induction heating system uses a magnetic field generated by a coil to directly induce eddy currents in the ferrous housing, which generates heat internally without direct thermal contact. This substitution of heating mechanism dramatically reduces energy consumption and melting time while maintaining effective ink melting.
Solution Approach 2:
The patent integrates the heating coil directly with the ferrous housing structure, merging the heating element and housing into a unified design. This integration eliminates the need for separate heating components and thermal transfer interfaces, reducing overall device volume while maintaining heating efficiency through direct electromagnetic coupling between the coil and ferrous material.
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 solution enables rapid and energy-efficient melting of phase change ink, maintaining it in a suitable liquid state for printing, improving printing efficiency and ink adhesion, while allowing for a more compact device design.
Implementation Method 1
The melting device includes a ferrous housing and an induction heating mechanism that utilizes alternating current to generate electromagnetic fields that heat the ink
Implementation Method 2
combined with a pressure system to manage ink flow and temperature, ensuring efficient melting and maintenance of the ink in a liquid state
Data Source
AI summary
A melting device melts solid ink into liquid ink by passing alternating current through an electrical conductor arranged in coils around a housing. The liquid ink passes from a reservoir, through a spool valve arrangement, and into first and second chambers. The spool valve arrangement only allows liquid ink into one chamber at a time. While the first chamber is being filled, pressure is applied to the second chamber. The pressure applied to the second chamber forces the liquid ink in the second chamber through a filter and an outlet. When the first chamber is filled to a predetermined level, pressure is no longer applied to the second chamber and is applied to the first chamber. The pressure applied to the first chamber moves the spool valve arrangement to block the first chamber. While pressure is applied to the first chamber, the second chamber is filled with liquid ink.