Ink Catcher Branching Structure for Vacuum Stability
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Solution Overview
Problem
Existing inkjet printer catchers face challenges in uniformly extracting ink across the width of a printhead, particularly when there are large differences in printed ink coverage, leading to issues like air ingestion and vacuum fluctuations that result in image pattern-dependent dripping.
Innovation Solution
The catcher design incorporates a flow channel with multiple branches, where a structure splits each branch into two parallel sections to allow fluid flow through both sections, which then merge downstream, reducing air ingestion and stabilizing vacuum levels by inhibiting slug flow and vacuum fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single fluid removal channel is used in the catcher, then the structure is simple, but air ingestion increases and vacuum stability deteriorates when there are large differences in printed ink coverage across the printhead width
Solution Approach 1:
The single fluid removal channel is segmented into multiple parallel branches. Each branch is further divided into multiple parallel sections by structures that split the flow path. This segmentation allows independent flow control in each section, preventing air ingestion and stabilizing vacuum levels across different ink coverage conditions.
Solution Approach 2:
The flow channel is transformed from a single two-dimensional path into a multi-dimensional network of parallel branches and sections. This dimensional expansion creates multiple flow pathways that can independently handle varying ink loads, improving vacuum stability without increasing overall structural complexity.
2Area of stationary object
If the fluid removal channel is extended to cover the entire length of the nozzle array, then ink extraction coverage is improved, but vacuum gradient increases and extraction uniformity deteriorates
Solution Approach 1:
The extended fluid removal channel is divided into multiple segments arranged in parallel branches. Each branch contains multiple sections that independently extract ink from different regions of the nozzle array. This segmentation maintains wide coverage while reducing the effective length of each individual flow path, thereby minimizing vacuum gradients and improving extraction uniformity.
Solution Approach 2:
Instead of using a single long channel that creates excessive vacuum gradient, multiple shorter parallel channels are used to achieve the same total coverage. This partial action approach distributes the extraction load across multiple independent pathways, preventing any single channel from developing excessive vacuum gradients.
3Stress or pressure
If ink removal ports are placed at each end of the catcher, then vacuum gradient is reduced, but extraction uniformity across the width still deteriorates under large ink coverage variations
Solution Approach 1:
The ink removal system is segmented from having ports only at ends to having multiple distributed ports arranged in parallel branches. Each branch has its own removal ports positioned to serve specific regions. This segmentation creates multiple independent vacuum zones that can maintain uniform extraction across the width even when ink coverage varies significantly.
Solution Approach 2:
Different sections of the parallel branch structure provide locally optimized extraction characteristics. Each branch and section can be designed with specific dimensions and port positions tailored to the local ink coverage requirements, ensuring uniform extraction across the entire width under varying print conditions.
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
This design effectively reduces image pattern-dependent dripping and maintains stable ink extraction across the printhead width, ensuring consistent ink return to the reservoir even under varying print conditions.
Implementation Method 1
by maintaining the vacuum, used for extracting the ink from the fluid removal channel below a certain critical level
Implementation Method 2
vacuum, used for extracting the ink from the fluid removal channel
Implementation Method 3
a stable meniscus can be established at the entrance of the fluid removal channel thereby preventing air from being drawn into the fluid removal channel
Implementation Method 4
a Coanda catcher, in which the non-impact drops impact a face of the catcher, and the ink flows around the Coanda radius to enter the fluid removal channel
Data Source
AI summary
A catcher (42) for collecting ink from non-printed drops and returning the ink to a fluid reservoir (40), the catcher includes a flow channel (47) having a plurality of branches (110); a structure to split a portion of each branch into two parallel sections to permit fluid to pass through either section; and wherein the flow of the two parallel sections (122) merge into a single flow downstream of the structure.