Ink Buildup Sensor Detecting Light Reduction in Continuous Ink Jet Print Heads
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Solution Overview
Problem
Ink buildup on surfaces adjacent to ink droplets in continuous ink jet printing systems can obstruct the flight path of ink droplets, leading to print quality issues and potential shutdowns, as existing systems lack effective detection and prevention mechanisms.
Innovation Solution
A sensor arrangement that detects ink buildup on internal surfaces of the print head by monitoring a reduction in sensed light, allowing for timely notification and automatic cleaning to prevent interference with print quality and EHT trips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous ink jet printing operates for extended periods, then productivity increases, but ink accumulation on internal surfaces occurs which obstructs droplet flight paths and degrades print quality
Solution Approach 1:
The optical sensor detects ink accumulation on internal surfaces before it becomes large enough to obstruct the droplet flight path. By performing detection in advance, the system can trigger cleaning operations proactively, preventing print quality degradation before it occurs and enabling continuous high-productivity operation.
Solution Approach 2:
The optical sensor continuously monitors the internal surfaces for ink accumulation and provides feedback to the control system. When accumulation exceeds a threshold, the system automatically initiates cleaning operations, creating a closed-loop control that maintains print quality while enabling continuous operation.
2Device complexity
If ink buildup is detected late, then detection simplicity is maintained, but droplet flight paths become obstructed causing shutdowns
Solution Approach 1:
An optical sensor acts as an intermediary detection mechanism that monitors ink accumulation on internal surfaces indirectly by measuring light transmission. This simple optical approach detects buildup early before it affects droplet flight paths, maintaining both detection simplicity and printing continuity through automatic cleaning triggers.
3Device complexity
If no detection mechanism is used, then device complexity remains low, but ink accumulation leads to EHT trips and process shutdowns
Solution Approach 1:
The patent replaces complex mechanical detection mechanisms with a simple optical sensor system that measures light transmission through the gutter. This substitution maintains low device complexity while providing reliable detection of ink accumulation that could cause EHT trips or shutdowns, thereby improving process stability.
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 sensor arrangement effectively detects ink accumulation before it affects print quality, enabling proactive maintenance and preventing shutdowns by automatically cleaning the buildup, thus ensuring continuous operation and maintaining print quality.
Implementation Method 1
An ink buildup sensor is configured to detect an accumulation of ink on a print head surface via a change in an amount of light sensed by the ink buildup sensor
Data Source
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AI summary
A continuous ink jet print head (10), including: an ink droplet generator (116) configured to emit an ink droplet (158) along an undeflected droplet flight path (30); a charge electrode (118) configured to impart a charge to the ink droplet; deflector plates (120A, 120B) adjacent the undeflected droplet flight path, downstream from the charge electrode, and configured to deflect the ink droplet to a deflected droplet flight path that lies within a range of deflected flight paths bounded by at least deflected droplet flight path and a most deflected droplet flight path; a gutter (122) configured to receive an ink droplet traveling along the undeflected droplet flight path; and an ink buildup sensor (102) configured to detect an accumulation of ink (140) relative to a droplet flight path disposed within the range of deflected flight paths.